2014 - Solved Problems in Facility Planning(1)

SOLVED PROBLEMS IN

FACILITY PLANNING & DESIGN

2014

Solved Problems in Facility Planning & Design

2014

FORMULAS IN FACILITY PLANNING & DESIGN

Facility Planning: determines Planning: determines how an activity’ activity’s tangible fixed assets best support achieving the activity activity’’s objectives. Facility Location: is the placement of a facility facili ty with with respect to customers, suppliers, supplier s, and other facilities faciliti es with which it interfaces. Structural Design: consists Design: consists of the building and services (e.g., gas, water, power, heat, light, air, sewage). Layout Design: consists Design: consists of all equipment, machinery, and furnishings within the structure. Handling System Design: consists consists of the mechanism mechanism by which which all interactions interactions required by the layout are satisfied (e.g., materials, personnel, information, information, and equipment handling systems). FACILITY LOCATION Factor Analysis Factor Analysis Technique WS =

WxS

Where: WS = weighted score for each factor for each facility plan or location W= appropriate appropri ate weight to each factor fact or (typically between between 0 to 1) based on the relative importance importanc e of each. S= assigned score score to each facility facilit y plan or location (typically between 0 to 100) with respect to each factor identified. identified. Compute the sum of the weighted scores scores for each f acility acility plan or location and choose a f acility plan or location with the highest score.

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FORMULAS IN FACILITY PLANNING & DESIGN

Facility Planning: determines Planning: determines how an activity’ activity’s tangible fixed assets best support achieving the activity activity’’s objectives. Facility Location: is the placement of a facility facili ty with with respect to customers, suppliers, supplier s, and other facilities faciliti es with which it interfaces. Structural Design: consists Design: consists of the building and services (e.g., gas, water, power, heat, light, air, sewage). Layout Design: consists Design: consists of all equipment, machinery, and furnishings within the structure. Handling System Design: consists consists of the mechanism mechanism by which which all interactions interactions required by the layout are satisfied (e.g., materials, personnel, information, information, and equipment handling systems). FACILITY LOCATION Factor Analysis Factor Analysis Technique WS =

WxS

Where: WS = weighted score for each factor for each facility plan or location W= appropriate appropri ate weight to each factor fact or (typically between between 0 to 1) based on the relative importance importanc e of each. S= assigned score score to each facility facilit y plan or location (typically between 0 to 100) with respect to each factor identified. identified. Compute the sum of the weighted scores scores for each f acility acility plan or location and choose a f acility plan or location with the highest score.

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Center-Of-Gravity Technique n

XiW i X=

i=1 _________________ n

W i i=1 n

YiW i Y=

i=1 _________________ n

W i i=1 Where: X, Y = coordinates coordinat es of the new facility facili ty at the center of of gravity. Xi, Yi = coordinates of the existing existing facility facility i. Wi = annual weight shipped from facility i. Load-Distance Technique n LD =

lidi

i=1 Where: LD = the load distance distance v alue li = the load expressed as a weight, number of trips, or units being shipped shipped from fr om the proposed site to location i. di = the distance between the proposed site and location locati on i. di =

2

2

(xi – x) – x) + (yi – y) – y)

Where: (x, y) = coordinates coordinat es of of the proposed site site (x i,yi) = coordinates of of the existing facility facility FACILITY DESIGN – SCHEDULE DESIGN Scrap Estimate Ok = Ok = Ik = I1 =

Ik - PkIk Ik (1 - Pk) Ok/ (1- Pk) On/ (1- P1) (1- P2)… (1(1- Pn)

Where: Ok = desired output of non-defective non-defective product from operation k Ik = production input to operation k

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Pk =

% of scrap produced in operation k

Yield with Reworking

O k or Yield = (Total Input) (%Good Units) + (Total Input) (1 – %Good Units) (%Reworked) Yield = (I) (%G) + (I) (1 – %G) (%R) Where I = planned number of units of product started in the production process %G = percentage of good units produced %R = percentage of defective units that are successfully reworked

Equipment Fraction F=

_____Total Time Required to Perform the Operation_______ Net Available Time to Complete the Operation per Machine

F=

SQ/ EHR

Where: F= S= Q= E= R=

number of machines required per period standard time per unit produced number of units to be produced period efficiency or actual performance expressed as percentage of standard time reliability of the machine expressed as percentage of ―up time‖

LAYOUT DESIGN Product Layout – Line Balancing D = OT / CT CT = OT / D Where: D= desired output rate OT = operating time per period CT = cycle time N=

__(D)(t)___ OT

Where: N= minimum number of work stations

t = D= OT = E=

sum of task times desired output rate operating time per period __ t___ N x CT

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Where: E= efficiency of the assembly line

t = N= CT =

sum of task times minimum number of work stations cycle time

Line Balancing Based on Incremental Utilization Method 

  

Add tasks to a workstation in order of task precedence one at a time until utilization is 100% or is observ ed to fall Then the above procedure is repeated at the next workstation for the remaining tasks Pro – Appropriate when one or more task times is equal to or greater than the cycle time Con – Might create the need f or extra equipment

Line Balancing Based on the Largest Number of Following Tasks 

 

Assign tasks to station 1, then 2, etc. in sequence. Keep assigning to a workstation ensuring that precedence is maintained and total work is less than or equal to the cycle time. Use the following rules to select tasks for assignment. Primary: Assign tasks in order of the largest number of following tasks Secondary (tie-breaking): Assign tasks in order of the longest operating time

Line Balancing Based on the Longest Task Time   

Adds tasks to a workstation one at a time in the order of task precedence. If two or more tasks tie for order of precedence, the one with the l ongest task time is added Conditions for its use: No task time can be greater than the cycle time There can be no duplicate workstations ◦ ◦

Process Layout – Block Diagramming     

Develop the load summary chart Rank the composite movements from highest to lowest Prepare the initial layout on the grid by placing one-by-one the two-way movements based on its rank. Compute the initial total number of non-adjacent loads Develop alternative layouts eliminating or minimizing the number of non-adjacent loads

Process Layout – Systematic Layout Planning         

Determine the total flow Rank the flows Combine flow and non-flow relationships Rank the combined points Develop the combined relationship chart Develop the relationship diagram Measure the effectiveness of the relationship diagram Develop the space relationship diagram Develop the layout

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Measuring Effectiveness of the Relationship Diagram Min Z =   Lij x Dij i j Where: Z= the least value of the product between Lij and Dij Lij = Load between departments i & j, often measured by the v alue of the vowel letter. A = 4, E = 3, I = 2, O = 1, U = 0, X = -1 X = -2 Dij = Distance between departments i & j Adjacent (Straight) – 1, Partial Adjacent (Diagonal) – 2, Non-Adjacent – 3 Process Layout - Manual CORELAP Algorithm 

 



Computerized Relationship Layout Planning (CORELAP) is a construction algorithm to create an activity relationship (REL) diagram or block layout from a REL chart. Each department (activity) is represented by a unit square. Numerical values are assigned to Corelap Values (CV’s): V(A) = 10,000, V(O) = 10, V(E) = 1,000, V(U) = 1, V(I) = 100, V(X) = -10,000. For each department, the Total Closeness Rating (TCR) is the sum of the absolute values of the relationships with other departments.

Procedure to Select Departments      

The first department placed in the layout is the one with the greatest TCR value. If a tie exists, choose the one with more A’s. If a department has an X relationship with the first one, it is placed last in the layout. If a tie exists, choose the one with the smallest TCR value. The second department is the one with an A relationship with the first one. If a tie exists, choose the one with the greatest TCR value. If a department has an X relationship with the second one, it is placed next-to-the-last or last in the layout. If a tie exists, choose the one with the smallest TCR value. The third department is the one with an A relationship with one of the placed departments. If a tie exists, choose the one with the greatest TCR value. The procedure continues until all departments have been placed.

Procedure to Place Departments 

Consider the figure below. Assume that a department is placed in the middle (position 0). Then, if another department is placed in position 1, 3, 5 or 7, it is ―fully adjacent‖ with the first one. If it is placed in position 2, 4, 6 or 8, it is ―partially adjacent‖.



For each position, Weighted Placement (WP) is the sum of the numerical values for all pairs of adjacent departments. The placement of departments is based on the following steps: The first department selected is placed in the middle. o



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o

o

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The placement of a department is determined by evaluating all possible locations around the current layout in counterclockwise order beginning at the ―western edge‖. The new department is located based on the greatest W P value.

Cellular Layout – Direct Clustering Algorithm  



 

Form the Parts-Machines Matrix. Order the rows and columns. Sum the Xs in each column (machine) and in each row (part) of the machine-part matrix. Order the rows (top to bottom) in descending order of the number of Xs in the rows and order the columns (left to right) in ascending order of the number of Xs in each. Where ties exist, break the ties in descending numerical sequence. Sort the columns. Beginning with the first row of the matrix, shift to the left of the matrix all columns having an X in the first row. Continue the process row-by-row until no f urther opportunity exists for shifting columns. Sort the rows. Column-by-column, beginning with the leftmost column, shift rows upward when opportunities exist to form blocks of Xs Form cells. Look for opportunities to form cells such that all processing for each part occurs in a single cell.

Facility Planning & Design A cr onyms : ALDEP - Automated Layout Design Program PLANET - Plant Layout Analysis and Evaluation Technique CORELAP - Computerized Relationship Layout Planning CRAFT - Computerized Relative Allocation of Facilities Technique DCA – Direct Clustering Algorithm

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ANSWER SHEET 1 PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE

NAME: _____________________________________

DATE: ____________________

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SCORE: __________ PASSING RATE: 75%

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/100 X 100 = __________%


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PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE 1. Using this space determination method, the present space requirements are converted to those required for the proposed layout. a. Roughed-Out Layout Method c. Space-Standards Method

b. Production-Center Method d. Converting Method

2. It is the most complex Flexible Manufacturing System layout which allows material to move among the machine centers in any order and typically includes several support stations such as tool interchange stations, pallet or fixture build stations, inspection stations, and chip/ coolant collection systems. a. Progressive Layout c. Closed-Loop Layout

b. Open-Field Layout d. Ladder Layout

3. Which of the following is a walking industrial vehicle? a. Tractor Trailer c. Pallet Truck

b. Straddle Carrier d. Hand Truck

4. How many lavatories do you need if a business organization has 41 to 60 employees? a. 2 c. 4

b. 3 d. 5

5. Drawing on the use of adjacency in the graph-based procedure, the _________________ is determined by summing the numerical values for all pairs of adjacent departments. a. Total Closeness Rating c. Total Adjacent Loads

b. Weighted Placement Value d. Total Flow

6. What is the objective of designing the product, process, and schedule in relation to f acilities planning? a. An effective production facility c. An efficient production system

b. An efficient operations management d. An effective operations management

7. A principle of m aterial handling which a m aterial handling facility should be the result of a cohesive and structured unit of specific courses of action to determine what material needs to be moved, when, and where it will be moved, and how it will be moved. a. Planning Principle c. Standardization Principle

b. System Principle d. Work Principle

8. Cellular layout is a type of layout which – a. Groups machines into department according to their function. b. Groups machines into small assembly lines that produce families of parts. c. Allows production of larger lots by reducing set-up time. d. Encourages the use of larger and efficient machinery. 9. What is the preferred area requirement of the President’s Office? a. 80 – 110 sq. ft. c. 150 – 250 sq. ft.

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b. 100 – 150 sq. ft. d. 250 – 400 sq. ft.


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10. The arrangement of all equipment, machinery, and furnishings within the structure. a. Facility Planning c. Layout Design

b. Facility Location d. Handling System Design

11. Which of the following is not a characteristic of product layouts? a. Standardized product c. High material handling costs

b. Sequential arrangements of machines d. Continuous production system

12. A graph is ___________ if it can be drawn so that its vertices are points in the plane and each edge can be drawn so that it intersects no other edges and passes through no other vertices. a. Open c. Planar

b. Close d. Non-Planar

13. How many urinals do you need if a church has 401 to 700 members? a. 2 c. 4

b. 3 d. 5

14. This program is used to generate and evaluate plant layout which does not restrict the final layout to uniform shape, nor does it allow fixing departments to certain locations, resulting in unrealistic layouts.

a. ALDEP - Automated Layout Design Program b. PLANET - Plant Layout Analysis and Evaluation Technique c. CORELAP - Computerized Relationship Layout Planning d. CRAFT - Computerized Relative Allocation of Facilities Technique 15. A __________ is the quantity in which material is normally moved. a. Distance c. Block

b. Unit Load d. Grid

16. It is an analog model of the operations and inspections required in assembling a product. a. Operation Process Chart c. Assembly Chart

b. Precedence Diagram d. Route Sheet

17. Which is not an automatic identification and recognition equipment? a. Bar Coding c. Magnetic Stripe

b. Radio Frequency Tag d. Voice Headset

18. Which of the following assumptions is not associated with planar location models? a. A plane is an adequate approximation of a sphere. b. Any point in the plane is a valid location to consider. c. Fixed costs can be i gnored. d. Travel costs are indirectly proportional to the planar distance used.

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19. The algorithm in Relationship Diagramming for determining the placement of the new activity begins at the ____________ of the partial layout and evaluates all possible locations in counterclockwise order. a. Northeastern Edge c. Eastern Edge

b. Northwestern Edge d. Western Edge

20. A product layout is characterized by – a. Narrow aisle ways c. Uses of general purpose equipment

b. Organized by function d. Produces goods to customer order

21. An approach to scoring models in computerized layout evaluation which attempts to approximate the ―cost‖ of flow between activities. a. Adjacency-Based Scoring c. Sequence-Based Scoring

b. Distance-Weighted Adjacency-Based Scoring d. Distance-Based Scoring

22. Which is not a characteristic of a process layout? a. Varied skills c. Low in-process

b. General purpose d. Machine location layout

23. In a __________________ layout, work stations are arranged according to the general function they perform without regard to any particular product. a. Product c. Fixed Position

b. Process d. Group Technology

24. A l ayout procedure which is based on the space relationship diagram, modifying considerations, and practical limitations, a number of alternative layouts are designed and ev aluated. a. Immer ’s Basic Steps c. Reed’s Plant Layout Procedure

b. Apple’s Plant Layout Procedure d. Muther ’s Systematic Layout Planning

25. It is a form of flow pattern that is applicable when it is desired to terminate the flow very near the point where the flow originated. a. Straight Line Flow c. U-Shaped Flow

b. L-Shaped Flow d. Circular Flow

26. It determines how an activity’s tangible fixed assets best support achieving the activity’s objectives. a. Facility Planning c. Layout Design


27. Which of the following is not a type of crane? a. Jib c. Hoist

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b. Gantry d. Stacker


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28. A type of layout used when the product is too large or cumbersome to move through the various processing steps. Consequently, rather than take the product to the processes, the processes are brought to the product. a. Fixed Position Layout c. Group Layout

b. Product Layout d. Process Layout

29. It allows the storage location for a particular product to change or ―float‖ over time. a. Shared Storage c. Dedicated Storage

b. Randomized Storage d. Class-Based Dedicated Storage

30. It is the design verification phase of product development and is used to demonstrate or prove aspects of a design. a. Prototyping c. Component part drawings

b. Bill of Materials d. Assembly drawing

31. Typically, layout design problems do not have well-defined, unique, and optimum solutions. We are interested in obtaining a/ an ___________________. a. Absolute solution c. Best possible solution

b. Most f avorable solution d. Satisfactory solution

32. How many lavatories do you need if a school has 101 to 200 students? a. 2 c. 4

b. 3 d. 5

33. This method evaluates different locations based on the load being transported and the distance. A single set of location coordinates is not identified. Instead, various locations are evaluated using a value that is measure of weight and distance. a. Factor Analysis Technique c. Load-Distance Technique

b. Center of Gravity Technique d. Relationship Diagram Technique

34. A programmable equipment connected by an automated material handling system and controlled by a central computer. a. Flexible Manufacturing System c. Mixed Model Assembly Lines

b. Group Technology d. Computer Method for Sequencing Operations

35. A layout construction program that uses the total closeness rating, which is the sum of all numerical values, assigned to the closeness relationships in a relationship chart between a department and all other departments.

a. ALDEP - Automated Layout Design Program b. PLANET - Plant Layout Analysis and Evaluation Technique c. CORELAP - Computerized Relationship Layout Planning d. CRAFT - Computerized Relative Allocation of Facilities Technique

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36. It is the sum of the weighted ratings between the new activity to be placed in the layout and its neighbors in the layout. a. Boundary Length c. Corner Count

b. Shape Ratio d. Placing Rating

37. It is the maximum work station time on the line. a. Desired Cycle Time c. Actual Cycle Time

b. Lead Time d. Balanced Time

38. Regions defined by a graph are referred to as ____________. a. Faces c. Adjacents

b. Edges d. Duals

39. A scale plan or model on which a thread is used to trace and measure the path of workers, materials or equipment during a specified sequence of events. a. String Diagram c. Relationship Chart

b. Plant Layout d. Block Diagram

40. What is the recommended range of stall width for standard car use? a. 8.5 to 9 ft. c. 9 to 10 ft.

b. 8 to 8.5 ft. d. 10 to 11 ft.

41. Which of the items below is not a container? a. Pallet c. Tote Pan

b. Skid d. Stretchwrap

42. It involves the assignment of specific storage locations or storage addresses for each product stored. a. Shared Storage c. Dedicated Storage


43. The arrangement of desired machinery of a plant, established or contemplated, in the way which will permit the easiest flow of materials, at the lowest cost and with the minimum of handling, in processing the product from the receipt of raw materials to the dispatch of t he finished product. a. Line Balancing c. Plant Layout

b. Block Diagram d. Relationship Chart

44. A tabular record for presenting quantitative data about the movements of workers, m aterials or equipment between any number of places over any given period of time. a. String Diagram c. Flow Diagram

b. From-To Chart d. Travel Chart

45. It tells us how much to produce and when to produce. a. Product Design c. Process Design

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b. Schedule Design d. Facility Design


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46. A layout procedure composed of three simple steps, which can be applied to any type of layout problem. These steps are: put the problem on paper, show lines of the flow, and convert flow lines to machine lines. a. Immer ’s Basic Steps c. Reed’s Plant Layout Procedure


47. The term ____________ is interpreted to mean adjacent. a. Open c. Line

b. Close d. Circle

48. How many water closets do you need if a business organization has 51 to 80 employees? a. 2 c. 4

b. 3 d. 5

49. What is the preferred area requirement of partitioned open for space—supervisor or m anager? a. 80 – 110 sq. ft. c. 150 – 250 sq. ft.

b. 100 – 150 sq. ft. d. 250 – 400 sq. ft.

50. A method of determining space requirements where each work station is a production facility having its own receiving, shipping, production, and storage space requirements. a. Space Standards Method c. Calculation Method

b. Conversion Method d. Flexible Method

51. How much space area requirements do you need if you will serve meals to 200 to 400 employees? a. 500 – 1000 sq. ft. c. 1,400 – 2,800 sq. ft.

b. 800 – 1600 sq. ft. d. 2,400 – 3,900 sq. ft.

52. Which of these conv eyors is not a belt conveyor? a. Chute Conveyor c. Telescoping Conveyor

b. Flat Conveyor d. Magnetic Conveyor

53. It summarizes whether a part will be purchased or produced, how the production of a part will be achieved, what equipment will be used, and how long it will take to perform each operation. a. Operation Process Chart c. Assembly Chart


54. A principle of material handling which material handling flow should be as low as possible within the requirements for effectiveness and efficiency of a material handling system. a. Planning Principle c. Standardization Principle


55. A type of layout used when production volumes for individual products are not sufficient thereby grouping products into logical product families. a. Fixed Position Layout c. Group Layout

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56. It provides information about the component parts of the product, make or buy decisions, part number, number of parts per product, and drawing references. a. Parts List c. Assembly Chart

b. Bill of Materials d. Route Sheet

57. It consists of mechanism by which all interactions required by the layout are satisfied. a. Facility Planning c. Layout Design


58. This a space determination method where templates or models are placed on the layout to obtain an estimate of the general configuration and space requirements. a. Roughed-Out Layout Method c. Space-Standards Method


59. A type of layout used when processes are located according to the processing sequence for the product. Material flows directly from a workstation to the adjacent workstation. a. Fixed Position Layout c. Group Layout


60. This location policy is referred to as _______________ if one particular time, different products use the same storage slot, albeit only one product occupies the slot when it is occupied. a. Shared Storage c. Dedicated Storage


61. It identifies the significant material flows and their corresponding paths. a. Factory Flow Analysis c. Line Analysis

b. Group Analysis d. Tooling Analysis

62. It is the simplest form of flow pattern which when employed in a plant, separate receiving and shipping crews are normally required. a. Straight Line Flow c. U-Shaped Flow


63. It contains the information concerning the structure of the product. a. Parts List c. Assembly Chart

b. Bill of Materials d. Engineering Drawing

64. Detailed design of individual products is influenced by? a. Function c. Manufacturing

b. Material d. All of these

65. It is reduced if the assembly process occurs in a single dimension. a. Product Dimension c. Cost of Assembly

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b. Parts Standard d. Number of Parts


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66. It depicts the probable movement of materials by corresponding lines superimposed on the floor plan of the area under study. a. Flow Process Chart c. Flow Diagram

b. Multiproduct Process Chart d. From-To Chart

67. They denote assembly operations or sub-assemblies. a. Lines with single link c. Circles with several links

b. Lines with several links d. Circles with single link

68. It consists of the mechanism by which all interactions required by the layout are satisfied e.g. materials, personnel, information, and equipment handling systems. a. Structure Design c. Layout Design

b. Handling System Design d. Facility Location

69. Which of the following tools is used primarily in determining machine location for a product layout? a. Line Balancing c. Assembly Diagram

b. Block Diagram d. Flow Diagram

70. Machines within a manufacturing cell are organized by – a. CORELAP c. Direct Clustering Algorithm

b. Relationship Diagramming d. Block Diagramming

71. Cycle time is not – a. Daily operating time divided by the desired production b. The maximum allowable time at each work station c. How often items roll off the assembly d. The time required to complete a product from start to finish 72. A common goal in designing process layouts is – a. Minimizing the number of workers b. Minimizing the idle time c. Minimizing material handling costs d. Balancing the work at each station 73. Mixed model assembly lines --a. Are simple to balance than single model assembly lines. b. Are usually U-shaped or S-shaped layouts. c. Require a m ore specialized workforce. d. Are most efficient when production of one type is completely finished before another type of model is introduced. 74. This drawing provides part specifications and dimensions in sufficient detail for manufacturing. a. Perspective Drawing c. Engineering Drawing

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b. Exploded Drawing d. Photograph of the Product


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75. It establishes the prerequisite assembly steps that must be completed before performing a given assembly step. a. Operation Process Chart c. Assembly Chart


76. It refers to the overall design concepts or morphologies embedded within the f acilities plan a. Parametric design c. Detailed design

b. Conceptual design d. Design Program

77. What is the recommended range of stall width for luxury and elderly car use? a. 8.5 to 9 ft. c. 9 to 10 ft.

b. 8 to 8.5 ft. d. 10 to 11 ft.

78. A principle of material handling which you try to reduce the ratio of equipment weight to product weight and suggest not to buy equipment that is bigger than necessary. a. Capacity Principle c. Unit Load Principle

b. Standardization Principle d. Dead W eight Principle

79. How much space area requirements do you need if you will serve meals to 401 to 800 employees? a. 500 – 1000 sq. ft. c. 1,400 – 2,800 sq. ft.

b. 800 – 1600 sq. ft. d. 2,400 – 3,900 sq. ft.

80. What is the recommended reception area that can accommodate a reception and 6 – 8 people? a. 125 – 200 sq. ft. c. 300 – 400 sq. ft.

b. 200 – 300 sq. ft. d. 400 – 500 sq. ft.

81. It is obtained by dividing the usable cube by the exterior envelope of the container. a. Container Nesting Ratio c. Trailer Space Utilization

b. Container Space Utilization d. Storage Space Efficiency

82. It is determined by dividing the overall container height by the nested height. a. Container Nesting Ratio c. Trailer Space Utilization


83. It is the ratio of usable cube divided by the storage cube. a. Container Nesting Ratio c. Trailer Space Utilization


84. The total number of containers along the length and width of the trailer and the container stacked vertically. a. Container Nesting Ratio c. Trailer Space Utilization

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85. A space determination method consists of a single machine plus all the associated equipment and space required for its operation. Work space, additional maintenance space, and storage space are added to the space requirements for the machine. a. Roughed-Out Layout Method c. Space-Standards Method


86. Which of the following is not an automated industrial vehicle? a. Unit Load Carrier c. Sorting Transfer Vehicle

b. Mobile Yard Crane d. Automated Electrified Vehicle

87. Which of the following is a type of an Operator-to-Stock Retrieval Equipment? a. Picking Cart c. Vertical Lift Module

b. Carousels d. Automatic Dispenser

88. It is a quantitative method of locating a facility at the center of the movement in a geographic area based on weight and distance. It identifies a set of coordinates designating a central location on a map relative to all other locations. a. Factor Analysis Technique c. Load-Distance Technique


89. Are physical restrictions on the order in which operations are performed on the assembly line? a. Precedence Requirements c. Balance Delays

b. Station Times d. Production Time Available

90. It is generally agreed that effective facilities planning can reduce material handling costs by --a. 5 – 10% c. 30 – 40%

b. 10 – 30% d. 50 – 70%

91. The quantity of equipment required for an operation. a. Equipment Effectiveness c. Equipment Fraction

b. Equipment Efficiency d. Equipment Planning

92. Which of the following is/ are way/s that we can accommodate a 20 second task in an 18 second cycle time? a. Share the task c. Use a more skilled worker

b. Use parallel work stations d. All of these

93. The term _____________ is used as a measure of the number of storages and retrievals performed per time period. a. Space c. Size

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b. Cost d. Throughput


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94. It takes a load summary chart and block diagram as input and then makes pair wise exchanges of departments until no improvements in cost or non-adjacency score can be found.

a. ALDEP - Automated Layout Design Program b. PLANET - Plant Layout Analysis and Evaluation Technique c. CORELAP - Computerized Relationship Layout Planning d. CRAFT - Computerized Relative Allocation of Facilities Technique 95. It i s an adaptation of the f amiliar mileage chart appearing on most road m aps which normally contains numbers representing some measure of the material flow between two machines, departments, buildings, or sites. a. Flow Process Chart c. Flow Diagram


96. It is the placement of a facility with respect to customers, suppliers, and other facilities with which it interfaces. a. Facility Planning c. Layout Design


97. It is the time required to complete an item. a. Desired Cycle Time c. Actual Cycle Time


98. It is a mechanized device to move materials in relatively large quantities between specific locations over a fixed path. a. Conveyor c. Pallet Truck

b. Unit Load Carrier d. Automated Guided Vehicle

99. It is a way to visualize the amount of movement that occurs between departments. a. Relationship Diagramming c. Line Balancing

b. Block Diagramming d. Digital Clustering Algorithm

100. It covers the system’s ability to be changed to produce new product types and ability to change the order of operations executed on a part. a. Routing Flexibility c. Machine Fl exibility

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b. Material Flexibility d. Flow Flexibility


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SOLVED PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE 1. Using this space determination method, the present space requirements are converted to those required for the proposed layout. a. Roughed-Out Layout Method c. Space-Standards Method


Answer: d. Conv erting Method 2. It is the most complex Flexible Manufacturing System layout which allows material to move among the machine centers in any order and typically includes several support stations such as tool interchange stations, pallet or fixture build stations, inspection stations, and chip/ coolant collection systems. a. Progressive Layout c. Closed-Loop Layout

b. Open-Field Layout d. Ladder Layout

Answer: b. Open-Field Layout 3. Which of the following is a walking industrial vehicle? a. Tractor Trailer c. Pallet Truck

b. Straddle Carrier d. Hand Truck

Answer: d. Hand Truck 4. How many lavatories do you need if a business organization has 41 to 60 employees? a. 2 c. 4

b. 3 d. 5

Answer: b. 3 5. Drawing on the use of adjacency in the graph-based procedure, the _________________ is determined by summing the numerical values for all pairs of adjacent departments. a. Total Closeness Rating c. Total Adjacent Loads

b. Weighted Placement Value d. Total Flow

Answer: c. Total Adjacent Loads 6. What is the objective of designing the product, process, and schedule in relation to f acilities planning? a. An effective production facility c. An efficient production system

b. An efficient operations management d. An effective operations management

Answer: c. An efficient production system 7. A principle of m aterial handling which a material handling facility should be the result of a cohesive and structured unit of specific courses of action to determine what material needs to be moved, when, and where it will be moved, and how it will be moved. a. Planning Principle c. Standardization Principle

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Answer: a. Planning Principle 8. Cellular layout is a type of layout which – a. Groups machines into department according to their function. b. Groups machines into small assembly lines that produce families of parts. c. Allows production of larger lots by reducing set-up time. d. Encourages the use of larger and efficient machinery. Answer: b. Groups machines into small assembly lines that produce families of parts. 9. What is the preferred area requirement of the President’s Office? a. 80 – 110 sq. ft. c. 150 – 250 sq. ft.

b. 100 – 150 sq. ft. d. 250 – 400 sq. ft.

Answer: d. 250 – 400 sq. ft. 10. The arrangement of all equipment, machinery, and furnishings within the structure. a. Facility Planning c. Layout Design


Answer: c. Layout Design 11. Which of the following is not a characteristic of product layouts? a. Standardized product c. High material handling costs

b. Sequential arrangements of machines d. Continuous production system

Answer: c. High material handling costs 12. A graph is ___________ if it can be drawn so that its vertices are points in the plane and each edge can be drawn so that it intersects no other edges and passes through no other vertices. a. Open c. Planar

b. Close d. Non-Planar

Answer: c. Planar 13. How many urinals do you need if a church has 401 to 700 members? a. 2 c. 4

b. 3 d. 5

Answer: c. 4 14. This program is used to generate and evaluate plant layout which does not restrict the final layout to uniform shape, nor does it allow fixing departments to certain locations, resulting in unrealistic layouts.


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Answer: b. PLANET 15. A __________ is the quantity in which material is normally moved. a. Distance c. Block

b. Unit Load d. Grid

Answer: b. Unit Load 16. It is an analog model of the operations and inspections required in assembling a product. a. Operation Process Chart c. Assembly Chart


Answer: c. Assembly Chart 17. Which is not an automatic identification and recognition equipment? a. Bar Coding c. Magnetic Stripe

b. Radio Frequency Tag d. Voice Headset

Answer: d. Voice Headset 18. Which of the following assumptions is not associated with planar location models? a. A plane is an adequate approximation of a sphere. b. Any point in the plane is a valid location to consider. c. Fixed costs can be i gnored. d. Travel costs are indirectly proportional to the planar distance used. Answer: d. Travel costs are indirectly proportional to the planar distance used. 19. The algorithm in Relationship Diagramming for determining the placement of the new activity begins at the ____________ of the partial layout and evaluates all possible locations in counterclockwise order. a. Northeastern Edge c. Eastern Edge

b. Northwestern Edge d. Western Edge

Answer: d. Western Edge 20. A product layout is characterized by – a. Narrow aisle ways c. Uses of general purpose equipment

b. Organized by function d. Produces goods to customer order

Answer: a. Narrow aisle ways 21. An approach to scoring models in computerized layout evaluation which attempts to approximate the ―cost‖ of flow between activities. a. Adjacency-Based Scoring c. Sequence-Based Scoring Answer: d. Distance-Based Scoring 22 | P a g e

b. Distance-Weighted Adjacency-Based Scoring d. Distance-Based Scoring


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22. Which is not a characteristic of a process layout? a. Varied skills c. Low in-process

b. General purpose d. Machine location layout

Answer: c. Low in-process 23. In a __________________ layout, work stations are arranged according to the general function they perform without regard to any particular product. a. Product c. Fixed Position

b. Process d. Group Technology

Answer: a. Product 24. A l ayout procedure which is based on the space relationship diagram, modifying considerations, and practical limitations, a number of alternative layouts are designed and evaluated. a. Immer ’s Basic Steps c. Reed’s Plant Layout Procedure


Answer: d. Muther ’s Systematic Layout Planning 25. It is a form of flow pattern that is applicable when it is desired to terminate the flow very near the point where the flow originated. a. Straight Line Flow c. U-Shaped Flow


Answer: d. Circular Flow 26. It determines how an activity’s tangible fixed assets best support achieving the activity’s objectives. a. Facility Planning c. Layout Design


Answer: a. Facility Planning 27. Which of the following is not a type of crane? a. Jib c. Hoist

b. Gantry d. Stacker

Answer: c. Hoist 28. A type of layout used when the product is too large or cumbersome to move through the various processing steps. Consequently, rather than take the product to the processes, the processes are brought to the product. a. Fixed Position Layout c. Group Layout Answer: a. Fixed Position Layout

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29. It allows the storage location for a particular product to change or ―float‖ over time. a. Shared Storage c. Dedicated Storage


Answer: b. Randomized Storage 30. It is the design verification phase of product development and is used to demonstrate or prove aspects of a design. a. Prototyping c. Component part drawings

b. Bill of Materials d. Assembly drawing

Answer: a. Prototyping 31. Typically, layout design problems do not have well-defined, unique, and optimum solutions. We are interested in obtaining a/ an ___________________. a. Absolute solution c. Best possible solution

b. Most f avorable solution d. Satisfactory solution

Answer: d. Satisfactory solution 32. How many lavatories do you need if a school has 101 to 200 students? a. 2 c. 4

b. 3 d. 5

Answer: a. 2 33. This method evaluates different locations based on the load being transported and the distance. A single set of location coordinates is not identified. Instead, various locations are evaluated using a value that is measure of weight and distance. a. Factor Analysis Technique c. Load-Distance Technique


Answer: c. Load-Distance Technique 34. A programmable equipment connected by an automated material handling system and controlled by a central computer. a. Flexible Manufacturing System c. Mixed Model Assembly Lines

b. Group Technology d. Computer Method for Sequencing Operations

Answer: a. Flexible Manufacturing System 35. A layout construction program that uses the total closeness rating, which is the sum of all numerical values, assigned to the closeness relationships in a relationship chart between a department and all other departments.


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Answer: c. CORELAP 36. It is the sum of the weighted ratings between the new activity to be placed in the layout and its neighbors in the layout. a. Boundary Length c. Corner Count

b. Shape Ratio d. Placing Rating

Answer: d. Placing Rating 37. It is the maximum work station time on the line. a. Desired Cycle Time c. Actual Cycle Time


Answer: c. Actual Cycle Time 38. Regions defined by a graph are referred to as ____________. a. Faces c. Adjacents

b. Edges c. Duals

Answer: a. Faces 39. A scale plan or model on which a thread is used to trace and measure the path of workers, materials or equipment during a specified sequence of events. a. String Diagram c. Relationship Chart

b. Plant Layout d. Block Diagram

Answer: a. String Diagram 40. What is the recommended range of stall width for standard car use? a. 8.5 to 9 ft. c. 9 to 10 ft.

b. 8 to 8.5 ft. d. 10 to 11 ft.

Answer: a. 8.5 to 9 ft. 41. Which of the items below is not a container? a. Pallet c. Tote Pan

b. Skid d. Stretchwrap

Answer: d. Stretchwrap 42. It involves the assignment of specific storage locations or storage addresses for each product stored. a. Shared Storage c. Dedicated Storage Answer: c. Dedicated Storage

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43. The arrangement of desired machinery of a plant, established or contemplated, in the way which will permit the easiest flow of materials, at the lowest cost and with the minimum of handling, in processing the product from the receipt of raw materials to the dispatch of t he finished finished product. a. Line Balancing c. Plant Layout

b. Block Diagram d. Relationship Chart

Answer: Answer: c. Plant Layout 44. A tabular record for presenting quantitativ quantitativ e data about the movements of workers, workers, materials or equipment between any number of places over any given period of time. a. String Diagram c. Flow Diagram

b. From-To Chart d. Travel Chart

Answer: Answer: d. Travel Chart 45. It tells us how m uch to produce and when to produce. a. Product Design c. Process Design

b. Schedule Design d. Facility Design

Answer: Answer: b. Schedule Design Design 46. A layout procedure composed of three simple steps, which can be applied to any type of layout problem. These steps are: put the problem on paper, show lines of the flow, and convert flow lines to machine lines. a. Immer ’s Basic Steps c. Reed’ Reed’s Plant Layout Procedure

b. Apple’ Apple’s s Plant Layout Procedure d. Muther ’s Systematic Layout Planning

Answer: Answer: a. Immer ’s Basic Steps 47. The term ____________ is interpreted to mean adjacent. adjacent. a. Open c. Line

b. Close d. Circle

Answer: Answer: b. Close 48. How many water closets do you need if a business organization has 51 to 80 employees? a. 2 c. 4

b. 3 d. 5

Answer: Answer: c. 4 49. What i s the preferred area requirement requirement of partitioned open for space— space—supervi supervisor sor or m anager? a. 80 – 80 – 110 110 sq. ft. c. 150 – 150 – 250 250 sq. ft. Answer: Answer: a. 80 – 80 – 110 110 sq. ft.

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b. 100 – 100 – 150 150 sq. ft. d. 250 – 250 – 400 400 sq. ft.


2014

50. A method of determining space requirements where each work station is a production facility having its own receiving, shipping, production, and storage space requirements. a. Space Standards Standards Method c. Calculation Method

b. Conversion Method d. Flexible Method

Answer: Answer: c. Calculation Method Method 51. How much space area requirements do you need if you will serv serv e meals to 200 to 400 employees? employees? a. 500 – 500 – 1000 1000 sq. ft. c. 1,400 – 1,400 – 2,800 2,800 sq. ft.

b. 800 – 800 – 1600 1600 sq. ft. d. 2,400 – 2,400 – 3,900 3,900 sq. ft.

Answer: Answer: b. 800 – 800 – 1600 1600 sq. ft. 52. Which of these conveyors is not a belt conveyor? a. Chute Conveyor c. Telescoping Conveyor

b. Flat Conveyor d. Magnetic Conveyor

Answer: Answer: a. Chute Conv Conv eyor 53. It summarizes whether a part will be purchased or produced, how the production of a part will be achieved, what equipment will be used, and how long it will take to perform each operation. a. Operation Process Chart c. Assembly Chart


Answer: Answer: d. Route Sheet 54. A principle of material handling which material handling flow should be as low as possible within the requirements for effectiveness and efficiency of a material handling system. a. Planning Principle c. Standardization Principle


Answer: Answer: d. Work Principle Principle 55. A type of layout used when production volumes for individual products are not sufficient thereby grouping products into logical product families. a. Fixed Position Layout c. Group Layout


Answer: Answer: c. Group Layout 56. It provides information about the component parts of the product, make or buy decisions, part number, number of parts per product, and drawing references. a. Parts List c. Assembly Chart Answer: Answer: a. Parts List List

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b. Bill of Materials d. Route Sheet


2014

57. It consists consists of mechanism by which all interactions required by the layout are satisfied. a. Facility F acility Planning Planning c. Layout Design


Answer: Answer: d. Handling System System Design 58. This a space determination method where templates or models are placed on the layout to obtain an estimate of the general configuration and space requirements. a. Roughed-Out Layout Method c. Space-Standards Space-Standards Method


Answer: Answer: a. Roughed-Out Layout Layout Method 59. A type of layout used when processes are located according to the processing sequence for the product. Material flows directly from a workstation to the adjacent workstation. a. Fixed Position Position Layout c. Group Layout


Answer: Answer: b. Product Layout 60. This location policy is referred to as _______________ if one particular time, different products use the same storage slot, albeit only one product occupies the slot when it is occupied. a. Shared Storage c. Dedicated Storage


Answer: Answer: a. Shared Storage 61. It identifies the significant material flows and their corresponding paths. a. Factory F actory Flow Analysis c. Line Analysis

b. Group Analysis d. Tooling Analysis

Answer: Answer: a. Factory Flow Analysis 62. It is the simplest form of flow pattern which when employed in a plant, separate receiving and shipping crews are normally required. a. Straight Line Flow c. U-Shaped Flow


Answer: Answer: a. Straight Line Flow 63. It contains the information concerning the structure of the product. a. Parts List c. Assembly Chart Answer: Answer: b. Bill of Materials Materials

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b. Bill of Materials d. Engineering Drawing


2014

64. Detailed design of individual products is influenced by? a. Function c. Manufacturing

b. Material d. All of these

Answer: d. All of these 65. It is reduced if the assembly process occurs in a single dimension. a. Product Dimension c. Cost of Assembly

b. Parts Standard d. Number of Parts

Answer: c. Cost of Assembly 66. It depicts the probable movement of materials by corresponding lines superimposed on the floor plan of the area under study. a. Flow Process Chart c. Flow Diagram


Answer: c. Flow Diagram 67. They denote assembly operations or sub-assemblies. a. Lines with single link c. Circles with several links

b. Lines with several links d. Circles with single link

Answer: c. Circles with several links 68. It consists of the mechanism by which all interactions required by the layout are satisfied e.g. materials, personnel, information, and equipment handling systems. a. Structure Design c. Layout Design

b. Handling System Design d. Facility Location

Answer: b. Handling System Design 69. Which of the following tools is used primarily in determining machine location for a product layout? a. Line Balancing c. Assembly Diagram

b. Block Diagram d. Flow Diagram

Answer: a. Line Balancing 70. Machines within a manufacturing cell are organized by – a. CORELAP c. Direct Clustering Algorithm

b. Relationship Diagramming d. Block Diagramming

Answer: c. Direct Clustering Algorithm 71. Cycle time is not – a. Daily operating time divided by the desired production b. The maximum allowable time at each work station c. How often items roll off the assembly 29 | P a g e


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d. The time required to complete a product from start to finish Answer: d. The time required to complete a product from start to finish 72. A common goal in designing process layouts is – a. Minimizing the number of workers b. Minimizing the idle time c. Minimizing material handling costs d. Balancing the work at each station Answer: c. Minimizing material handling costs 73. Mixed model assembly lines --a. Are simple to balance than single model assembly lines. b. Are usually U-shaped or S-shaped layouts. c. Require a m ore specialized workforce. d. Are most efficient when production of one type is completely finished before another type of model is introduced. Answer: b. Are usually U-shaped or S-shaped layouts. 74. This drawing provides part specifications and dimensions in sufficient detail for manufacturing. a. Perspective Drawing c. Engineering Drawing

b. Exploded Drawing d. Photograph of the Product

Answer: c. Engineering Drawing 75. It establishes the prerequisite assembly steps that must be completed before performing a given assembly step. a. Operation Process Chart c. Assembly Chart


Answer: b. Precedence Diagram 76. It refers to the overall design concepts or morphologies embedded within the f acilities plan a. Parametric design c. Detailed design

b. Conceptual design d. Design Program

Answer: a. Parametric design 77. What is the recommended range of stall width for luxury and elderly car use? a. 8.5 to 9 ft. c. 9 to 10 ft. Answer: c. 9 to 10 ft.

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b. 8 to 8.5 ft. d. 10 to 11 ft.


2014

78. A principle of material handling which you try to reduce the ratio of equipment weight to product weight and suggest not to buy equipment that is bigger than necessary. a. Capacity Principle c. Unit Load Principle

b. Standardization Principle d. Dead W eight Principle

Answer: d. Dead Weight Principle 79. How much space area requirements do you need if you will serve meals to 401 to 800 employees? a. 500 – 1000 sq. ft. c. 1,400 – 2,800 sq. ft.

b. 800 – 1600 sq. ft. d. 2,400 – 3,900 sq. ft.

Answer: c. 1,400 – 2,800 sq. ft. 80. What is the recommended reception area that can accommodate a reception and 6 – 8 people? a. 125 – 200 sq. ft. c. 300 – 400 sq. ft.

b. 200 – 300 sq. ft. d. 400 – 500 sq. ft.

Answer: b. 200 – 300 sq. ft. 81. It is obtained by dividing the usable cube by the exterior envelope of the container. a. Container Nesting Ratio c. Trailer Space Utilization


Answer: b. Container Space Utilization 82. It is determined by dividing the overall container height by the nested height. a. Container Nesting Ratio c. Trailer Space Utilization


Answer: a. Container Nesting Ratio 83. It is the ratio of usable cube divided by the storage cube. a. Container Nesting Ratio c. Trailer Space Utilization


Answer: d. Storage Space Efficiency 84. The total number of containers along the length and width of the trailer and the container stacked vertically. a. Container Nesting Ratio c. Trailer Space Utilization Answer: c. Trailer Space Utilization

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85. A space determination method consists of a single machine plus all the associated equipment and space required for its operation. Work space, additional maintenance space, and storage space are added to the space requirements for the machine. a. Roughed-Out Layout Method c. Space-Standards Method


Answer: b. Production-Center Method 86. Which of the following is not an automated industrial vehicle? a. Unit Load Carrier c. Sorting Transfer Vehicle

b. Mobile Yard Crane d. Automated Electrified Vehicle

Answer: b. Mobile Yard Crane 87. Which of the following is a type of an Operator-to-Stock Retrieval Equipment? a. Picking Cart c. Vertical Lift Module

b. Carousels d. Automatic Dispenser

Answer: a. Picking Cart 88. It is a quantitative method of locating a facility at the center of the movement in a geographic area based on weight and distance. It identifies a set of coordinates designating a central location on a map relative to all other locations. a. Factor Analysis Technique c. Load-Distance Technique


Answer: b. Center of Gravity Technique 89. Are physical restrictions on the order in which operations are performed on the assembly line? a. Precedence Requirements c. Balance Delays

b. Station Times d. Production Time Available

Answer: a. Precedence Requirements 90. It is generally agreed that effective facilities planning can reduce m aterial handling costs by --a. 5 – 10% c. 30 – 40%

b. 10 – 30% d. 50 – 70%

Answer: b. 10 – 30% 91. The quantity of equipment required for an operation. a. Equipment Effectiveness c. Equipment Fraction Answer: c. Equipment Fraction

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b. Equipment Efficiency d. Equipment Planning


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92. Which of the following is/ are way/s that we can accommodate a 20 second task in an 18 second cycle time? a. Share the task c. Use a more skilled worker

b. Use parallel work stations d. All of these

Answer: d. All of these 93. The term _____________ is used as a measure of the number of storages and retrievals performed per time period. a. Space c. Size

b. Cost d. Throughput

Answer: d. Throughput 94. It takes a load summary chart and block diagram as input and then makes pair wise exchanges of departments until no improvements in cost or non-adjacency score can be found.

a. ALDEP - Automated Layout Design Program b. PLANET - Plant Layout Analysis and Evaluation Technique c. CORELAP - Computerized Relationship Layout Planning d. CRAFT - Computerized Relative Allocation of Facilities Technique Answer: d. CRAFT 95. It i s an adaptation of the f amiliar mileage chart appearing on most road maps which normally contains numbers representing some measure of the material flow between two machines, departments, buildings, or sites. a. Flow Process Chart c. Flow Diagram


Answer: d. From-To Chart 96. It is the placement of a facility with respect to customers, suppliers, and other facilities with which it interfaces. a. Facility Planning c. Layout Design


Answer: b. Facility Location 97. It is the time required to complete an item. a. Desired Cycle Time c. Actual Cycle Time


Answer: b. Lead Time 98. It is a mechanized device to move materials in relatively large quantities between specific locations over a fixed path. a. Conveyor c. Pallet Truck

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b. Unit Load Carrier d. Automated Guided Vehicle


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Answer: a. Conv eyor 99. It is a way to visualize the amount of movement that occurs between departments. a. Relationship Diagramming c. Line Balancing

b. Block Diagramming d. Digital Clustering Algorithm

Answer: b. Block Diagramming 100. It covers the system’s ability to be changed to produce new product types and ability to change the order of operations executed on a part. a. Routing Flexibility c. Machine Fl exibility Answer: c. Machine Flexibility

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b. Material Flexibility d. Flow Flexibility


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ANSWER SHEET 2 PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE

NAME: _____________________________________

DATE: ____________________

1. _______

21. _________

41. _________

61. _________

81. _________

2. _______

22. _________

42. _________

62. _________

82. _________

3. _______

23. _________

43. _________

63. _________

83. _________

4. _______

24. _________

44. _________

64. _________

84. _________

5. _______

25. _________

45. _________

65. _________

85. _________

6. _______

26. _________

46. _________

66. _________

86. _________

7. _______

27. _________

47. _________

67. _________

87. _________

8. _______

28. _________

48. _________

68. _________

88. _________

9. _______

29. _________

49. _________

69. _________

89. _________

10. _______

30. _________

50. _________

70. _________

90. _________

11. _______

31. _________

51. _________

71. _________

91. _________

12. _______

32. _________

52. _________

72. _________

92. _________

13. _______

33. _________

53. _________

73. _________

93. _________

14. _______

34. _________

54. _________

74. _________

94. _________

15. _______

35. _________

55. _________

75. _________

95. _________

16. _______

36. _________

56. _________

76. _________

96. _________

17. _______

37. _________

57. _________

77. _________

97. _________

18. _______

38. _________

58. _________

78. _________

98. _________

19. _______

39. _________

59. _________

79. _________

99. _________

20. _______

40. _________

60. _________

80. _________

100. _________

SCORE: __________ PASSING RATE: 75%

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/100 X 100 = __________%


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PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE 1. Belinda Fashion Wear i s a small chain of stores specializing in fashion clothing. The company currently has five stores in Manila, Quezon City, and Caloocan, and it wants to open new store in of four new mall locations in the other nearby cities. A consulting firm has been hired to help the company decide where to locate new store. The company has indicated five factors that are important to its decision, including proximity of a college, community median income, mall vehicle traffic flow and parking, quality and number of stores in the mall, and proximity of other malls or shopping areas. The consulting firm had the company weight the importance of each factor. The consultant had visited each potential location and rated them according to each factor, as follows: Location factors College proximity Median income Vehicle traffic Mall quality and size Proximity of other shopping

Weight 0.30 0.25 0.25 0.10 0.10

Mall 1 40 75 60 90 80

Mall 2 60 80 90 100 30

Mall 3 90 65 79 80 50

Mall 4 60 90 85 90 70

Given that all sites have basically the same leasing cost and labor and operating cost, what is the recommended location based on rating f actors? a. Mall 1 c. Mall 3

b. Mall 2 d. Mall 4

2. Zachtech Computers manufacture computer components such as chips, circuit boards, motherboards, keyboards, LCD panels, and the like and sells them around the world. It wants to construct a new warehouse/distribution center in Asia to serve emerging Asian markets. It has identified sites in Shanghai, Hong Kong and Singapore and has rated the important location factors for each site as follows: Location Factors Political Stability Economic Growth Port Facilities Container support Land and construction cost Transportation/Distribution Duties and tariffs Trade regulations Airline Service Area roads

Weight 0.25 0.18 0.15 0.10 0.08 0.08 0.07 0.05 0.02 0.02

Shanghai 50 90 60 50 90 50 70 70 60 60

Hong Kong 60 70 95 80 20 80 90 95 80 70

Singapore 90 75 90 90 30 70 90 95 70 80

Recommend a site including its total score rating based on these location factors and ratings. a. Hongkong, 72 c. Singapore, 81

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b. Hongkong, 82 d. Shanghai, 79


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3. Cradle University is going to construct a new student center and athletic complex that will include a bookstore, post office, theaters, markets, mini-mall, meeting rooms, swimming pool, and weight and exercise rooms. The university administration has hired a site selection specialist has identified four sites on campus and has rated important location factors for each site as follows: Location Factors Proximity to housing Student traffic Parking availability Plot size, terrain Infrastructure Off-campus accessibility Proximity dining facilities Visitor traffic Landscape/aesthetics

Weight 0.23 0.22 0.16 0.12 0.10 0.06 0.05 0.04 0.02

South 70 75 90 80 50 90 60 70 50

West A 90 80 60 70 60 70 80 80 40

West B 65 60 80 90 40 70 70 65 60

East 85 85 70 75 60 70 90 55 70

Recommend a best site based on these location f actors and ratings. a. South b. West A c. West B d. East 4. Zhan Electronics is going to construct new P1.2 billion semi-conductor plant and has selected four Export Processing Zone Areas as potential sites. The important location factors and ratings for each town are as follows: Location Factors Work Ethics Quality of Life Labor Laws/Unionization Infrastructure Education Labor skill & Education Cost of Living Taxes Incentive Package Government Regulation Environmental Regulation Transportation Space for Expansion Urban Proximity

Weight 0.18 0.16 0.12 0.10 0.08 0.07 0.06 0.05 0.05 0.03 0.03

Sta. Rosa 80 75 90 60 80 75 70 60 90 40 65

Lipa 90 85 90 50 90 65 80 70 95 50 60

Bataan 70 95 60 60 85 70 85 55 70 65 70

Subic 75 90 70 70 95 80 75 60 80 55 80

0.03 0.02 0.02

90 90 60

80 95 90

95 90 70

80 90 80

Recommend a site based on these location factors and ratings. a. Sta. Rosa c. Bataan

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b. Lipa c. Subic


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5. Joehanna Drug Store Chain wishes to build a new warehouse to serve the whole Quezon. At the moment, it is looking at three possible locations. The factors, weights, and ratings being considered are given below:

Factor Nearness to markets Labor cost Taxes Nearness to suppliers

Weights 20 5 15 10

Ratings Candelaria 4 8 8 10

Lucena 7 8 9 6

Lukban 5 4 7 10

Which city should they choose? a. Candelaria, 340 c. Lukban 325

b. Lucena, 375 d. Lukban, 385

6. The Charlie Forwarding Company wants to build a new distribution center in Central Luzon. The center needs to be in the vicinity of uncongested Aurora, Bataan, and Nueva Ecija. The coordinates of this sites and the number of weekly packages that flow to each are as follows: Aurora X = 17 Y = 30 W = 17,000

Bataan X = 20 Y=8 W = 12,000

Nueva Ecija X = 30 Y = 14 W = 9,000

What are the coordinates of the center of these 3 provinces? a. (25, 22) c. (24, 17)

b. (18, 22) d. (21, 19)

7. James Company is attempting to determine the location for a new outlet mall. The region where the outlet mall will be constructed includes four towns, which together have a sizable population base. The grid map coordinates of the four towns in Cavite and the populations of each are as f ollows: Town Rosario Dasmarinas Trece Martirez Silang

X 30 50 10

Y 60 40 70

Population (10,000s) 6.5 4.2 5.9

40

30

3.5

Determine best location for the outlet mall using the center-of-gravity method. a. (32, 56) c. (30, 54)

b. (33, 55) d. (31, 52)

8. Ray-Mart, a discount store chain, wants to build a new superstore in an area in Batangas near four small towns with population between 8,000 and 42,000. The coordinates (in miles) of these four towns and the m arket population in each are as follows: Bauan X = 12 Y = 20 W = 26,000

38 | P a g e

Ibaan X = 18 Y = 18 W = 14,000

Mabini X = 30 Y=7 W = 9,500

Laurel X = 32 Y = 25 W = 12,000


2014

Determine the coordinates of the best site using the center of gravity technique. a. (24, 21) b. (23, 22)

b. (21, 20) d. (20, 19)

9. Caloy Distribution Center in Quezon City is due to be replaced with a much l arger, more modern facility that can handle the tremendous needs that have developed with the city’s growth. Fresh produce travels to the seven store locations several times a day making site selection critical for efficient distribution. Using the data in the following table, determine the map coordinates for the proposed new distribution center. Store Locations Timog Avenue Banawe St. West Avenue Tomas Morato St. Visayas Avenue Libis Cubao a. (8, 7) c. (7, 9)

Map Coordinates (x,y) (10, 5) (3, 8) (4, 7) (15, 10) (13, 3) (1, 12) (5, 5)

Truck Round Trips per Day 3 3 2 6 5 3 10

b. (9, 7) d. (7, 8)

10. The f ollowing table gives the map coordinates and the shipping loads for a set of cities that we wish to connect though a central ―hub.‖ Near what map coordinates should the hub be located? City A B C D E F G a. (7, 5) c. (4, 8)

Map Coordinate (x,y) (5, 10) (6, 8) (4, 9) (9, 5) (7, 9) (3, 2) (2, 6)

Shipping Load 5 10 15 5 15 10 5

b. (8, 4) d. (5, 7)

11. The Inah Burger restaurant chain uses a distribution center to prepare the food ingredients it provides its individual restaurants. The company is attempting to determine the location for new distribution center that will service five restaurants. The grid-map coordinates of the five restaurants and the annual numbers of 40-foot trailer trucks transported to each restaurant are as follows: Restaurants 1 2 3 4 5

X 100 210 250 300 400

Y 300 180 400 150 200

Annual Truck Shipments 30 25 15 20 18

Determine the coordinates of the location using the center-of-gravity method. a. (233, 242) c. (243, 231)

39 | P a g e

b. (236, 244) c. (245, 230)


2014

12. The Inah Burger restaurant chain in the previous problem i s considering three potential sites. With the following grid-map coordinates for its new distribution center: A(350, 300). B. (150, 250), and C (250, 300). Determine the best location using the load-distance formula. a. Site A, LD = 15,205 c. Site C, LD = 15,570

b. Site B, LD = 15,325 c. Site C, LD = 15,255

13. Marla Homes, a home improvement/ building supply chain, is going to build a new warehouse facility to serve its stores in six Metro Manila Cities - Taguig, Pasig, Mandaluyong, Makati, Pasay, and Quezon City. The coordinates of this cities (in miles), using Manila, as the origin (0,0) of a set of coordinates, and the annual truck loads that supply each city as shown as f ollows. Determine the best site using the center- gravity technique. Pasig

Taguig

Mandaluyong

Makati

Pasay

X = 15 Y = 85 W = 160

X =42 Y = 145 W = 90

X = 88 Y = 145 W = 105

X = 125 Y = 140 W = 35

X = 135 Y = 125 W = 60

a. (77, 104) c. (79, 106)

Quezon City X = 180 Y = 18 W = 75

b. (80, 107) d. (81, 105)

14. Refer to problem no. 13, Marla Homes base has two parcel of land, Site A & B in Metro Manila. Use the load-distance technique to determine which would be the best site with its load-distance value. Given: Site A B

X 88 13

Y 80 127

a. Site A with LD = 38,986 c. Site B with LD = 44,121

b. Site A with LD = 40,391 d. Site B with LD = 43,542

15. Roy Automobile Accessories, a manufacturer of automobile fan belts is considering three locations— Subic, Clark, and Laguna for a new plant. Cost studies indicate that fixed costs per year at the sites are P30,000.00, P60,000.00, and P110,000.00, respectively; and variable cost are P75.00 per unit, P45.00 per unit, and P25.00 per unit, respectively. The expected selling price of the f an belt produced is P120.00. The company wishes to find the most economical location for an expected volume of 2,000 units per year. a. Subic, P180,000.00 c. Clark, P150,000.00

b. Subic, P140,000.00 d. Laguna, P160,000.00

16. A plastic firm has four work centers (A, B, C, and D) in series with individual capacities (units per day) and actual output as shown.

A 450

B 390

C 360

D 400

actual output = 306/ day

What is the process capacity? a. 306 c. 450

40 | P a g e

b. 360 d. 1,600


2014

17. Refer to Problem no. 16, what is the process efficiency? a. 19% c. 68%

b. 22.5% d. 85%

18. Dennis Furniture Company manufactures four-drawer oak cabinets in six stages. In the first stage, the boards forming the walls of the cabinets are cut; in the second stage the front drawer panels are woodworked; in the third stage the boards are sanded and finished; in the fourth stage the boards are cleaned, stained, and painted with a clear finish; in the fifth stage the hardware for pulls, runners, and fittings is installed; and in the final stage the cabinets are assembled. Inspection occurs at each stage of the process, and the average percentages of good-quality units are as follows: Stage 1 2 3 4 5 6

Average Percentage Good Quality 87% 91% 94% 93% 93% 96%

The cabinets are produced in weekly production runs with a product input for 300 units. Determine the weekly product yield of good-quality cabinets. a. 186 c. 312

b. 288 d. 486

19. Refer to problem no. 18, what would weekly product input have to be in order to achieve a final weekly product yield of 300 cabinets? a. 186 c. 312

b. 288 d. 486

20. The Jelo Motor Company, motors are produced in a three-stage process. Motors are inspected following each stage with percentage yields of good quality in process units as follows:

1

Average Percentage Good Quality 0.96

2

0.98

3

0.95

Stage

The company wants to know the daily product yield for product input of 250 units per day. a. 263 c. 223

b. 238 d. 280

21. Refer to problem no. 20, how many input units it would have to start with each day to result in a final daily yield of 250 good quality units? a. 263 c. 223

41 | P a g e

b. 238 d. 280


2014

22. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000 stov es if the good quality of each stov e is 88%? a. 13,200 c. 125,000

b. 1,800 d. 17,045

23. Lara Company operates a small telephone order system for a catalog of its clothing products. The catalog orders are processed in four stages. Errors can be made i n orders at any of these stages, and the average percentages of errors that occur at each stage are as follows. Stage 1 2 3 4

%Error 19% 16% 10% 8%

If an average of 460 telephone orders is processed each day, how many errorless orders will result? a. 112 c. 244

b. 259 d. 129

24. Liam Manufacturing Company has a weekly product input of 2,800 units. The average percentage of good-quality product is 87 percent. Of the poor quality products 60 percent can be reworked and sold as good-quality products. Determine the weekly product output? a. 2,654 c. 1,462

b. 5,364 d. 3,218

25. Assume that production volume is 1,600 pieces per day, the standard time is 0.004 hour per piece, 8 working hours per day, setup time at 0.2 hr per day, and scrap rate of 0.10. Find the fractional machine number. a. 1.12 c. 0.91

b. 0.85 d. 1.21

26. A product requires two sequential machine operations. The first takes 3.5 minutes and the defect percentage is 12. The second takes 6.0 minutes and the defect percentage is 7. In another similar plant belonging to the same company, past annual data on identical operations and working conditions indicate that a total of 2,198 hours due to set up of machines and 2,052 hours due to machine unavailability due to maintenance per year. Assuming 250 work days per year and a daily shift of 10 hours, it is desired to determine the minimum fractional number of machines to manufacture 50,000 units per year. a. 4 c. 6

b. 5 d. 7

27. Eric Explosives Company is considering the expansion of a solid-propellant manufacturing process by adding more 1-ton capacity curing furnaces. Each batch (1 ton) of propellant must undergo 30 minutes of furnace time, including load and unload operations. However, the furnace is used only 80 percent of the time due to power restrictions in the other parts of the system. The required output for the new layout i s to be 16 tons per shift (8 hours). Plant (system) efficiency is estimated at 50 percent of system capacity. Determine the number of furnaces required. a. 3 c. 1

42 | P a g e

b. 4 d. 5


2014

28. Refer to problem no. 27, estimate the percentage of time the f urnaces will be idled. a. 20% c. 33%

b. 25% d. 67%

29. Charmz Developing Agency must determine how many photo-enlarger cubicles are required to maintain an output of 200 good prints per hour. The set-up and exposure time can theoretically be done in 2 minutes per print, but operators are on the average only 90 percent efficient and, in addition, 5 percent of the prints must be scrapped and redone. Also, the cubicles can be utilized for enlarging only 70 percent of the time. What is the required process capacity in prints per hour? a. 212 c. 211

b. 250 d. 200

30. Refer to problem no. 29, what average output per hour can be expected f rom each cubicle, taking its use factor and efficiency into account? a. 211 c. 19

b. 30 d. 200

31. Refer to problem no. 29, how many enlarger cubicles are required? a. 14 c. 16

b. 10 d. 12

32. Dason Plastics manufacturer must acquire some molding machines capable of producing 160,000 good parts per year. They will be installed in a production line that normally produces 20 percent rejects because of the tight aerospace specifications. Assume that it takes 90 seconds to mold each part and the plant operates 2,000 hours per year. If the molding machines are used only 50 percent of the time and are 90 percent efficient, what actual (usable) molding machine output per hour would be achieved? a. 40 c. 45

b. 18 d. 20

33. Refer to problem no. 32, how many molding machines would be required? a. 4 c. 6

b. 8 d. 12

34. Given: Year i. ii. iii. iv. v.

Demand (units) 220,000 275,000 380,000 420,000 565,000

% Scrap: 3% Standard Time: 2 minutes per unit Target Machine Efficiency: 90% Machine Breakdown: 30 minutes per day Operation Schedule: 8am – 4pm daily schedule/ 20 working days per month How many machines you will acquire/ buy on Year 1? a. 5 c. 2 43 | P a g e

b. 7 d. 9


2014

35. Refer to problem 34, how many machines you will acquire/ buy on Year 2? a. 5 c. 1

b. 7 d. 9

36. Refer to problem no. 34, how many machines you will acquire/ buy on Year 3? a. 5 c. 3

b. 7 d. 9


b. 10 d. 9


b. 10 d. 13

39. A team of Industrial Engineers conducted a work sampling of identical machines being used for a manufacturing company and they have observed the following: % Idleness Machine 1 20% Machine 2 35% Machine 3 15% Machine 4 55% The machines are running based on the schedule of operation per shift. Shift Schedule: 6am – 2pm/ 2pm – 10pm/ 10pm – 6am Break Time: 1-hr meal break and 15 minutes coffee or short break per shift. Compute for the number of machines required in a given shift. a. 1 c. 3

b. 2 d. 4

40. Mandy Garments produces T-shirts for road races. They need to acquire some new stamping machines to produce 30,000 good T-shirts per month. Their plant operates 200 hours per month, but the new machines will be used for T-shirts only 60 percent of the time and the output usually includes 5 percent that are ―seconds‖ and unusable. The stamping operation takes 1 minute per T-shirt, and the stamping machines are expected to have 90 percent efficiency when considering adjustments, changeover of patterns, and unavoidable downtime. How many machines are required? a. 5 c. 7

b. 6 d. 8

41. During one-8-hour shift, 770 non-defective parts are desired from a fabrication operation. The standard time for the operation is 12 minutes. Because the machine operators are unskilled, the actual time it takes to perform the operation is 25 mi nutes and, on the average, one-sixth of the parts that begin fabrication are scrapped. Assuming that each of the machines used for this operation will not be available for 45 minutes each shift and there is a probability of 0.05 that each machine will breakdown, determine the number of machines required. a. 50 c. 54 44 | P a g e

b. 52 d. 56


2014

42. Nestor Briefcases is an exclusive producer of handcrafted, stylish cases. Priding itself on its earlier reputation, the company assembles each case with care and attention to detail. This laborious process requires the completion of six primary work elements, which are listed here. Work Element A Tan leather B Dye leather C Shape case D Mold hinges and fixtures E Install hinges and fixtures F Assemble case

Precedence A B C, D E

Time (min) 30 15 10 5 10 10

If the demand is 50 cases per 40-hour week, compute the cycle time for the process. a. 30 c. 46

b. 40 d. 48

43. Refer to problem no. 42, compute the lead time required for assembling one briefcase. a. 30 c. 80

b. 48 d. 45

44. Refer to problem no. 42, calculate the theoretical minimum number of workstations. a. 3 c. 4

b. 2 d. 1

45. Refer to problem no. 42, balance the line based on the most number of followers. a. 35

45

AD

BCEF

45

35

AB

CDEF

30

30

A

BCD

b.

c.

45 | P a g e

20

EF


2014

d. 30

25

A

BC

25

DEF

46. Refer to problem no. 42, compute the line’s efficiency. a. 89% c. 81%

b. 83% d. 93%

47. Refer to problem no. 42, suppose the demand for briefcases increases to 80 cases per week. Calculate a new cycle time. a. 30 c. 50

b. 35 d. 45

48. Refer to problem no. 47, bal ance the line based on the l ongest task time a. 35

45

AD

BCEF

45

35

AB

CDEF

30

30

A

BCD

30

25

A

BC

b.

c. 20

EF

d. 25

DEF

49. Refer to problem no. 47, calculate the new efficiency of the manufacturing process. a. 89% c. 81% 46 | P a g e

b. 83% d. 93%


2014


b. 2 d. 1

51. Pepper & Mys Bakeshop has set a production quota of 600 party cakes per 40-hour workweek. Use the following information to compute for the cycle time. Predecessor Work Element A B A C B D A, E E F C, D

Performance Time (min) 1 2 2 4 3 4

a. 3 c. 4

b. 16 d. 13

52. Refer to problem no. 51, compute the theoretical minimum number of workstations. a. 5 c. 2

b. 3 d. 4

53. Refer to problem no. 51, balance the line using incremental utilization method a. 3

AB

3.25

CDEF

3.25

CDEF

3.25

CDEF

b. 2.5

ABC

2.5

5.5

5.5

ABC

DEF

DEF

3.25

3.25

3.25

c. 3

AB

47 | P a g e

CEDF

C ED F

CEDF

3.25

C ED F


2014

d. 3.0

AB

3.0

AB

3.25

3.25

C ED F

CEDF

3.25

CEDF

54. Refer to problem no. 51, calculate the efficiency of the assembly line. a. 95% c. 80%

b. 90% d. 83%

55. The Hanzel Pizza is revamping its order processing and pizza-making procedures. In order to deliver fresh pizza fast, six elements must be completed. Work Element

Precedence

A Receive order B Shape dough C Prepare toppings D Assemble pizza E Bake pizza F Deliver pizza

A A B, C D E

Time (min) 2 1 2 3 3 3

If the demand is 120 pizzas per night (5:00 p.m. to 1:00 a.m.), compute the cycle time for the process. a. 4 c. 14

b. 3 d. 13

56. Refer to problem no. 55, compute the lead time for the process. a. 4 c. 14

b. 3 d. 13

57. Refer to problem no. 55, Calculate the theoretical minimum number of workstations. a. 2 c. 4

b. 3 d. 5

58. Refer to problem no. 55, bal ance the line using the most number of followers method. a. 3

5

3

3

AB

CD

E

F

3

2

3

3

3

AB

C

D

E

F

b.

48 | P a g e


2014

c. 4

1

3

3

3

AC

B

D

E

F

4

4

3

3

AC

BD

E

F

d.

59. Refer to problem no. 55, compute the efficiency of the line. a. 88% c. 89%

b. 91% d. 93%

60. Refer to problem no. 55, suppose demand increases to 160 pizzas per night. What is the new cycle time? a. 4 c. 14

b. 3 d. 13

61. Refer to problem no. 60, bal ance the line based on the l ongest task time method. a. 3

5

3

3

AB

CD

E

F

3

2

3

3

3

AB

C

D

E

F

4

1

3

3

3

AC

B

D

E

F

b.

c.

49 | P a g e


2014

d. 4

4

3

3

AC

BD

E

F

62. Refer to problem no. 60, calculate the new theoretical minimum number of workstations. a. 2 c. 4

b. 3 d. 5

63. Neren’s Eye Care, Inc., is a full-service optical supplier that sells eyeglasses, contact lenses, protective eye apparel to opticians. Bogs’ job is to assemble custom-ordered lenses into eyeglasses for customers. Sales have been good lately, and Bogs has been assembling 100 glasses a day. The manager of Neren’s asked Bogs to write down the precedence requirements and approximate assembly times for each step in the assembly process. The data are shown here. Element Description

Precedence

A

-

Time (min) 1.0

A B B C, D

1.0 0.4 0.4 2.0

Inspect right and left lens for scratches and proper match Pop lens into frame Position right side piece and attach to frame Position left side piece and attach to frame Package

B C D E

Assuming an 8-hour workday, how long does it take Bogs to assemble one pair of glasses? a. 2 c. 4

b. 2.4 d. 4.8

64. Refer to problem no. 63, Neren’s anticipates a surge in demand with the opening of its own retail outlets. If the assembly process is set up as an assembly line, what is the maximum number of eyeglasses that can be assembled in one day, regardless of the number of workers hired? a. 200 c. 100

b. 240 d. 480

65. Refer to problem no. 64, what is the efficiency of the line? a. 80% c. 100%

50 | P a g e

b. 91% d. 95%


2014

66. Prof. Jone has assigned 15 cases in his Seminar class to be completed in a 15 week semester. The students, of course, are moaning and groaning that the caseload cannot possibly be completed in the time allotted. Prof. Jone sympathetically suggests that the students work in groups and learn to organize their work efficiently. Knowing when a situation is hopeless, the students make a list of the tasks that have to be completed in preparing a case. These tasks are listed here, along with precedence requirements and estimated time in days. Assuming students will work 5 days a week on this assignment, how many students should be assigned to each group? Element Description

Precedence

Time (days)

A b c d e f

a a b d c, e

1 4 3 1 4 4

Read case Gather data Search literature Load in data Run computer analysis Write/type case a. 3 c. 5

b. 4 d. 6

67. The precedence diagram and task times (in minutes) for assembling Reyson’s Stamp Pad are shown here. Set up an assembly line to produce 125 stamp pads in a 40-hour week. What is the cycle time? 8

5

A

B

F

C

D

E

6

10

2

J

4

H

G

9

K

7

3

I

5

2

a. 10 c. 61

b. 19.2 d. 2


19

11

12

ABC

DFG

EH I

JK

19

19

18

5

ACB

DGF

EHJ

IK

b.

51 | P a g e


2014

c. 19

17

13

12

ABC

DEG

FHI

JK

19

16

14

12

ACB

DFE

GH I

JK

d.

69. The work elements, precedence requirements, and time requirements to assemble a picture frame are shown here. What is the cycle time capable of producing 1,600 frames per 40-hour week? Element Description

Precedence

A B C D E F G H I

A, B C, D E, F F, G D

Attach left frame side to top of frame Attach right frame side to bottom of frame Attach left and right frame subassemblies Cut 8-inch x 10-inch glass Cut 8-inch x 10-inch cardboard Place glass into frame Place cardboard into frame Secure cardboard and glass Apply descriptive label to glass a. 1.5 c. 0.10

Time (min) 0.35 0.35 0.70 0.50 0.50 0.20 0.20 0.50 0.10

b. 0.70 d. 3.4

70. Refer to problem no. 69, balance the assembly line based on the computed cycle time using incremental utilization method a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

52 | P a g e

CEF

0.70

GH


2014

c. 1.40

ABC

1.40

DEFG

0.60

HI

d. 1.45

DE AI

1.45

BCFG

0.50

H

71. Refer to Problem No. 70, what is the maximum output per week? a. 1,600 c. 1,750

b. 1,715 d. 1,656

72. Refer to problem no. 69, balance the assembly line based on the computed cycle time using most number of followers method. a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

CEF

0.70

GH

c. 1.40

ABC

1.40

DEFG

0.60

HI

d. 1.45

DE AI

1.45

BCFG

0.50

H


53 | P a g e

b. 1,715 d. 1,656


2014

74. Refer to problem no. 69, balance the assembly line based on the computed cycle time using longest task time method. a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

CEF

0.70

GH

c. 1.40

ABC

1.40

DEFG

0.60

HI

d. 1.45

DE AI

1.45

BCFG

0.50

H


b. 1,715 d. 1,656

76. Refer t o problem no. 69, calculate the m aximum number of frames that can be assembles each week. a. 2,557 c. 3,567

b. 2,452 d. 3,429

77. Refer to problem no. 76, rebalance the line for maximum production. Assuming one worker per workstation. How many workers would be required? a. 5 c. 6

b. 4 d. 3

78. Refer to problem no. 76, assume the company can sell as many frames as can be produced. If workers are paid P60.00 an hour. What is the total cost per frame? a. 1.67 c. 6.17

54 | P a g e

b. 1.47 d. 7.14


2014

79. The Racela Finance Corporation has set a processing quota of 80 insurance claims per 8-hour day. The claims process consists of five elements, which are detailed in the following table. Racela has decided to use an assembly line arrangement to process the forms and would like to make sure they have set up the line in the most efficient fashion. Calculate the cycle time required to meet the processing quota. Element Precedence A B A C B D A E C, D

Performance Time (min) 4 5 2 1 3

a. 5 c. 15

b. 6 d. 16

80. Refer to problem no. 79, determine how many claims can actually be processed on your line. a. 60/ day c. 80/ day

b. 70/ day d. 90/ day

81. A firm must produce 40 units/day during an 8-hour workday. Tasks, tim es, and predecessor activities are given below. Task A B C D E F G H Total

Time (Minutes) 2 2 8 6 3 10 4 3 38 minutes

Predecessor(s) A C B D, E F G

Determine the cycle time to produce the 40 units per day. a. 10 c. 12

b. 38 d. 20

82. Thomas Santos, manager of a metropolitan branch office of the state department of motor vehicles, attempted to perform an analysis of the driver ’s license renewal operations. He identified the steps and associated times required to perform each step as follows: Job A. Review renewal application for correctness B. Process and record payment C. Check file violations and restrictions D. Conduct eye test E. Photograph applicant F. Issue temporary license

Average Time to perform (seconds) 15 30 60 40 20 30

Santos found that each step was assigned to a different person. Santos also found that jobs A, B, C, and D were handled by general clerks who were each paid P270.00 per hour. Job E was by a photographer paid P360.00 per hour. Job F, the i ssuing of temporary licenses, was required by state 55 | P a g e


2014

policy to be handled by a uniformed motor vehicle officer. Officers were paid P405.00 per hour, but they could be assigned to any j ob except photography. A review of the jobs indicated that job A, reviewing the application for correctness, had to be performed before any other step could be taken. Similarly, job F, issuing the temporary license, could not be performed until all the other steps were completed. The checking of file violations and restrictions could be performed while the applicant is having his eye test. The branch offices were charged P450.00 per hour for each camera to perform photography. Determine the maximum number of applications per hour that can be handled by the present configuration of the process? a. 60 c. 120

b. 90 d. 180

83. Refer to problem no. 82, how many applications can be processed per hour if a second clerk is added to check for violations? a. 60 c. 120

b. 90 d. 180

84. In addition to problem no. 83, assuming one more clerk is added to job D, what is the maximum number of applications the process can handle? a. 60 c. 120

b. 90 d. 180

85. Refer to problem no. 82, what is the required cycle time of the process to accommodate 180 applications per hour? a. 15 c. 40

b. 20 d. 60

86. Refer to problem no. 82, compute for the costs per application per hour involved in the current process. a. 30.60 c. 23.40

b. 18.90 d. 38.25

87. Refer to problem no. 84, for the costs per application per hour involved in the alternative process. a. 30.60 c. 23.62

b. 18.90 d. 38.25

88. Given: From/To

A

A

B

C

15

50

E

20

75

C

50

120

E F

50 110

100 100

F 125

B D

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D

120


2014

Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building? a. A

D

B

C

E

F

b. C

F

B

E

A

D

c. B

E

A

F

C

D

d. D

C

B

E

A

F

89. Given: Number of loads per week Department 1 2 3 4 5 6

57 | P a g e

1

2

3

50

100 30

4

5

6 20

50

10

20

100 50


2014

Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the l ayout of your building? a. 1

2

6

4

3

5

5

2

1

b.

4

3

6

2

6

5

3

4

1

6

3

4

1

5

2

c.

d.

90. Given: Number of loads per week Department 1. Administration 2. Social services 3. Institutions 4. Accounting 5. Education 6. Internal audit

58 | P a g e

1

2

3

4

5

6

3

6

5

6

10

8

1

1

3

9 2 1


2014

Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building? a. 4

6

1

2

5

3

b. 3

2

6

4

5

1

c. 1

5

4

3

6

2

6

3

2

5

1

4

d.

91. Given: Loads/day From/To A B A B

30 30

D

E

60

20 30

C

80

D

40

E

59 | P a g e

C


2014

Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the l ayout of your building? a. C

A

D

E

C

B

D

A

B

D

E

A

A

E

C

B

B

b.

E

c.

C

d.

D

60 | P a g e


2014

92. Matthew Design Company has been asked to design the layout for a newly constructed office building of one of its clients. The closeness matrix showing the daily trips between its six department offices is given below. Department

Trips between Departments 1

1

2

3

25

90

4

5

165

2

105

3

125

4

25

5

6

125 105

6 Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building? a. 3

1

5

6

4

2

2

5

3

b.

4

1

6

c. 5

3

1

6

4

2

d. 1

3 61 | P a g e

6

5

2

4


2014

93. Given: Flow between Departments (Number of Moves) 7 8 1 2 3 4 5 6 20 75 175 150 80

Departments 1. Shipping and receiving 2. Plastic molding stamping

90

100

120

125

350

3. Metal forming 4. Sewing department

25

25

5. Small toy assembly

180

187

6. Large toy assembly

374

103 7

7. Painting 8. Mechanism assembly


1

2

6

4

3

7

8

1

7

5

2

6

3

8

4

b.

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2014

c. 4

5

6

1

3

2

8

7

6

4

7

8

2

5

1

3

d.

94. Given: From/To

Stores

Stores

Turning

Milling

Press

Plate

Assembly

6

12

9

1

4

Turning

3

Warehouse

4

Milling

7

2

Press

3

1

1

4

3

Plate Assembly

1

3

7

1

Warehouse Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?

a.

63 | P a g e

Press

W arehouse

W arehouse

Plate

Milling

Stores

Turning


b.

Turning

Stores

Milling

Press

W arehouse

Plate

Assembly

c.

Assembly

W arehouse

Turning

Plate

Press

Assembly

Stores

d.

Milling

Assembly

Plate

W arehouse

Turning

Stores

Press

95. Based on the relationship chart below, what is it recommended layout?

64 | P a g e

2014


a. 4

6

1

5

2

3

6

4

1

5

3

2

b.

c.

2

3

6

1

5 4

d.

6

3

2

5

1 4

96. Based on the relationship chart below, what is its recommended layout?

65 | P a g e

2014


a. 5

3

1

2

4

6

7

1

3

4

2

6

7

3

1

2

4

7

5

1

3

2

4

5

7

b.

5

c.

6

d.

6

97. Given: Legend: A I U

CV Values 10,000 100 0

Activity

Legend E O X

CV Values 1,000 10 -1,000

Area (sq. m)

1. W ood cutting

1,280

2. Receiving

560

A E I 3. Framing

1,280

U

I 4. Upholstery

U

1,120 E

5. Fabric storage

960

6. Fabric cutting

960

7. Sewing

640

E

U 8. Shipping

66 | P a g e

800

9. Offices

800

10. General Storage

480

U O E

O

U I

A A

X U

E

U U

X

U

I U U U

U

I

U

U

U I U

2014


Distance between departments: Adjacent = 1, Partial Adjacent = 0.5, Non-Adjacent = 0 Using CORELAP, what is Total Closeness Rating (TCR) Value of Department 1? a. 10,000 c. 12,000

b. 11,000 d. 14,000

98. In reference to problem no. 97, what activity is the first to be placed on the grid? a. 7 c. 5

b. 2 d. 6

99. In reference to problem no. 98, what is your final layout? a.

2

10

5

6

1

3

7

8

4

9

10

1

7

3

5

6

8

9

2

b.

4

67 | P a g e

2014


2014

c.

7

10

1

4

8

9

2

3

5

6

10

5

6

8

4

7

1

3

9

d.

2

100. Given:

Machines

A B C D E F G H I J K L

Parts-Machines Matrix Parts 1 2 3 4 5 x x x x x x x x x x x x x x x x x

6 x

7

8

x x x x x x

x

x x

Using Digital Clustering Algorithm (DCA), prepare the final cell formation with additional machines, if needed.

68 | P a g e


a.

5

6

1

4

X

X

X

X

2

8

7

A

X

X

X

H

X

X

X

B

X

X

J

X

X

L

X

X

X

G

X

X

D

K

3

X

C

X

X

F

X

X

I

X

X

E

X

b.

5

6

1

4

X

X

X

X

A

X

X

X

H

X

X

X

B

X

X

J

X

X

D

2

8

X

X

X

X

L1 G K

7

3

X

L2

X

C

X

X

F

X

X

I

X

X

E

c.

X

5

6

1

4

X

X

X

X

7

3

2

8

A

X

X

X

H

X

X

X

B

X

X

J

X

C

X X

X

F

X

X

I

X

X X

X

L

X

X

G

X

X

D

E

X

K

d.

X

5

6

1

4

X

X

X

X

7

3

A

X

X

X

H

X

X

X

B

X

X

J

X

X

C

X

X

F

X

X

I

X

X

D

E1

2

8

X x

x

L

X

X

G

X

X

E2

K

69 | P a g e

X

2014


2014

SOLVED PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE 1. Belinda Fashion Wear i s a small chain of stores specializing in fashion clothing. The company currently has five stores in Manila, Quezon City, and Caloocan, and it wants to open new store in of four new mall locations in the other nearby cities. A consulting firm has been hired to help the company decide where to locate new store. The company has indicated five factors that are important to its decision, including proximity of a college, community median income, mall vehicle traffic flow and parking, quality and number of stores in the mall, and proximity of other malls or shopping areas. The consulting firm had the company weight the importance of each f actor. The consultant had visited each potential location and rated them according to each factor, as follows: Location factors College proximity Median income Vehicle traffic Mall quality and size Proximity of other shopping

Weight 0.30 0.25 0.25 0.10 0.10

Mall 1 40 75 60 90 80

Mall 2 60 80 90 100 30

Mall 3 90 65 79 80 50

Mall 4 60 90 85 90 70

Given that all sites have basically the same leasing cost and labor and operating cost, what is the recommended location based on rating f actors? a. Mall 1 c. Mall 3

b. Mall 2 d. Mall 4

Answer: d. Mall 4 Location factors College proximity Median income Vehicle traffic Mall quality and size Proximity of other shopping

Mall 1 12.00 18.75 15.00 9.00 8.00

Mall 2 18.00 20.00 22.50 10.00 3.00

Mall 3 27.00 16.25 19.75 8.00 5.00

Mall 4 18.00 22.50 21.25 9.00 7.00

TOTAL

62.75

73.50

76.00

77.75

2. Zachtech Computers manufacture computer components such as chips, circuit boards, motherboards, keyboards, LCD panels, and the like and sells them around the world. It wants to construct a new warehouse/distribution center in Asia to serve emerging Asian markets. It has identified sites in Shanghai, Hong Kong and Singapore and has rated the important location factors for each site as follows: Location Factors Political Stability Economic Growth Port Facilities Container support Land and construction cost Transportation/Distribution Duties and tariffs Trade regulations Airline Service Area roads

70 | P a g e

Weight 0.25 0.18 0.15 0.10 0.08 0.08 0.07 0.05 0.02 0.02

Shanghai 50 90 60 50 90 50 70 70 60 60

Hong Kong 60 70 95 80 20 80 90 95 80 70

Singapore 90 75 90 90 30 70 90 95 70 80


2014

Recommend a site including its total score rating based on these location factors and ratings. a. Hongkong, 72 c. Singapore, 81

b. Hongkong, 82 d. Shanghai, 79

Answer: c. Singapore, 81 Location Factors Political Stability Economic Growth Port Facilities Container support Land and construction cost Transportation/Distribution Duties and tariffs Trade regulations Airline Service Area roads Total

Shanghai 12.50 16.20 9.00 5.00 7.20 4.00 4.90 3.50 1.20 1.20 64.70 = 65

Hong Kong 15.00 12.60 14.25 8.00 1.60 6.40 6.30 4.75 1.60 1.40 71.90 = 72

Singapore 22.50 13.50 13.50 9.00 2.40 5.60 6.30 4.75 1.40 1.60 80.55 = 81

3. Cradle University is going to construct a new student center and athletic complex that will include a bookstore, post office, theaters, markets, mini-mall, meeting rooms, swimming pool, and weight and exercise rooms. The university administration has hired a site selection specialist has identified four sites on campus and has rated important location factors for each site as follows: Location Factors Proximity to housing Student traffic Parking availability Plot size, terrain Infrastructure Off-campus accessibility Proximity dining facilities Visitor traffic Landscape/aesthetics

Weight 0.23 0.22 0.16 0.12 0.10 0.06 0.05 0.04 0.02

South 70 75 90 80 50 90 60 70 50

West A 90 80 60 70 60 70 80 80 40

West B 65 60 80 90 40 70 70 65 60

East 85 85 70 75 60 70 90 55 70

Recommend a best site based on these location f actors and ratings. a. South b. West A c. West B d. East Answer: d. East Location Factors Proximity to housing Student traffic Parking availability Plot size, terrain Infrastructure Off-campus accessibility Proximity dining facilities Visitor traffic Landscape/aesthetics Total

71 | P a g e

South 16.10 16.50 14.40 9.60 5.00 5.40 3.00 2.80 1.00 73.80

West A 20.70 17.60 9.60 8.40 6.00 4.20 4.00 3.20 0.80 74.50

West B 14.95 13.20 12.80 10.80 4.00 4.20 3.50 2.60 1.20 67.25

East 19.55 18.70 11.20 9.00 6.00 4.20 4.50 2.20 1.40 76.75


2014

4. Zhan Electronics is going to construct new P1.2 billion semi-conductor plant and has selected four Export Processing Zone Areas as potential sites. The important location factors and ratings for each town are as follows: Location Factors Work Ethics Quality of Life Labor Laws/Unionization Infrastructure Education Labor skill & Education Cost of Living Taxes Incentive Package Government Regulation Environmental Regulation Transportation Space for Expansion Urban Proximity

Weight 0.18 0.16 0.12 0.10 0.08 0.07 0.06 0.05 0.05 0.03 0.03

Sta. Rosa 80 75 90 60 80 75 70 60 90 40 65

Lipa 90 85 90 50 90 65 80 70 95 50 60

Bataan 70 95 60 60 85 70 85 55 70 65 70

Subic 75 90 70 70 95 80 75 60 80 55 80

0.03 0.02 0.02

90 90 60

80 95 90

95 90 70

80 90 80

Recommend a site based on these location factors and ratings. a. Sta. Rosa c. Bataan

b. Lipa c. Subic

Answer: b. Lipa Location Factors Work Ethics Quality of Life Labor Laws/Unionization Infrastructure Education Labor skill & Education Cost of Living Taxes Incentive Package Government Regulation Environmental Regulation Transportation Space for Expansion Urban Proximity Total

72 | P a g e

Sta. Rosa 14.4 12.0 10.8 6.00 6.40 5.25 4.20 3.00 4.50 1.20 1.95 2.70 1.80 1.20 75.40

Lipa 16.2 13.6 10.8 5.00 7.20 4.55 4.80 3.50 4.75 1.50 1.80 2.40 1.90 1.80 79.80

Bataan 12.6 15.2 7.20 6.00 6.80 4.90 5.10 2.75 3.50 1.95 2.10 2.85 1.80 1.40 74.15

Subic 13.5 14.4 8.40 7.00 7.60 5.60 4.50 3.00 4.00 1.65 2.40 2.40 1.80 1.60 77.85


2014

5. Joehanna Drug Store Chain wishes to build a new warehouse to serve the whole Quezon. At the moment, it is looking at three possible locations. The factors, weights, and ratings being considered are given below:


Weights 20 5 15 10

Ratings Candelaria 4 8 8 10

Lucena 7 8 9 6

Lukban 5 4 7 10

Which city should they choose? a. Candelaria, 340 c. Lukban 325

b. Lucena, 375 d. Lukban, 385

Answer: b. Lucena, 375


Weights

Ratings Candelaria

Lukban

Weighted Ratings Candelaria Lucena

Lucena

Lukban

20

4

7

5

80

140

100

5 15

8 8

8 9

4 7

40 120

40 135

20 105

10

10

6

10

100

60

100

340

375

325

Sum of W eighted ratings:

6. The Charlie Forwarding Company wants to build a new distribution center in Central Luzon. The center needs to be in the vicinity of uncongested Aurora, Bataan, and Nueva Ecija. The coordinates of this sites and the number of weekly packages that flow to each are as follows: Aurora X = 17 Y = 30 W = 17,000

Bataan X = 20 Y=8 W = 12,000

Nueva Ecija X = 30 Y = 14 W = 9,000

What are the coordinates of the center of these 3 provinces? a. (25, 22) c. (24, 17) Answer: d. (21, 19) X= X= Y= Y=

(17) (17,000) + (20) (12,000) + (30) (9,000) 17,000 + 12,000 + 9,000 21.03 = 21 (30) (17,000) + (8) (12,000) + (14) (9,000) 17,000 + 12,000 + 9,000 19.26 = 19

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b. (18, 22) d. (21, 19)


2014

7. James Company is attempting to determine the location for a new outlet mall. The region where the outlet mall will be constructed includes four towns, which together have a sizable population base. The grid map coordinates of the four towns in Cavite and the populations of each are as f ollows: Town Rosario Dasmarinas Trece Martirez Silang

X 30 50 10

Y 60 40 70

Population (10,000s) 6.5 4.2 5.9

40

30

3.5

Determine best location for the outlet mall using the center-of-gravity method. a. (32, 56) c. (30, 54)

b. (33, 55) d. (31, 52)

Answer: c. (30, 54) X = (30(6.5) + 50(4.2) + 10(5.9) + 40(3.5)) / (6.5 + 4.2 + 5.9 + 3.5) X = 604/20.1 X = 30.05 = 30 Y = (60(6.5) + 40(4.2) + 70(5.9) + 30(3.5)) / (6.5 + 4.2 + 5.9 + 3.5) Y = 1076/20.1 Y = 53.53 = 54 8. Ray-Mart, a discount store chain, wants to build a new superstore in an area in Batangas near four small towns with population between 8,000 and 42,000. The coordinates (in miles) of these four towns and the m arket population in each are as follows: Bauan X = 12 Y = 20 W = 26,000

Ibaan X = 18 Y = 18 W = 14,000

Mabini X = 30 Y=7 W = 9,500

Laurel X = 32 Y = 25 W = 12,000

Determine the coordinates of the best site using the center of gravity technique. a. (24, 21) b. (23, 22)

b. (21, 20) d. (20, 19)

Answer: d. (20, 19) X = (12(26,000) + 18(14,000) + 30(9,500) + 32(12,000)) / (26,000 + 14,000 + 9,500 + 12,000) X = 1,233,000/61,500 X = 20.05 = 20 Y = (20(26,000) + 18(14,000) + 7(9,500) + 25(12,000)) / (26,000 + 14,000 + 9,500 + 12,000) Y = 1,138,500/61,500 Y = 18.51 = 19

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2014

9. Caloy Distribution Center in Quezon City is due to be replaced with a much l arger, more modern facility that can handle the tremendous needs that have developed with the city’s growth. Fresh produce travels to the seven store locations several times a day making site selection critical for efficient distribution. Using the data in the following table, determine the map coordinates for the proposed new distribution center. Store Locations Timog Avenue Banawe St. West Avenue Tomas Morato St. Visayas Avenue Libis Cubao

Map Coordinates (x,y) (10, 5) (3, 8) (4, 7) (15, 10) (13, 3) (1, 12) (5, 5)

a. (8, 7) c. (7, 9)

Truck Round Trips per Day 3 3 2 6 5 3 10

b. (9, 7) d. (7, 8)

Answer: a. (8, 7) New Distribution Center should be located at: C x = (10 x 3) + (3 x 3) + (4 x 2) + (15 x 6) + (13 x 5) + (1 x 3) + (5 x 10) = 255 = 8 3 + 3 + 2 + 6 + 5 + 3 +10 32 Cy = (5 x 3) + (8 x 3) + (7 x 2) + (10 + 6) + (3 x 5) + (12 x 3) + (5 x 10) = 214 = 7 3 + 3 + 2 + 6 + 5 + 3 + 10 32 10. The f ollowing table gives the map coordinates and the shipping loads for a set of cities that we wish to connect though a central ―hub.‖ Near what map coordinates should the hub be located? City A B C D E F G

Map Coordinate (x,y) (5, 10) (6, 8) (4, 9) (9, 5) (7, 9) (3, 2) (2, 6)

a. (7, 5) c. (4, 8)

Shipping Load 5 10 15 5 15 10 5

b. (8, 4) d. (5, 7)

Answer: d. (5, 7) The new hub should be located close to: C x= (5 x 5) + (6 x 10) + (4 x 15) + (9 x 5) + (7 x 15) + (3 x 10) + (2 x 5) = 335 = 5 5 +10 + 15 + 5 + 15 +10 + 5 65 Cy = (10 x 5) + (8 x 10) + (9 x 15) + (5 + 5) + (9 x 15) + (2 x 10) + (6 x 5) = 475 = 7 5 + 10 + 15 + 5 + 15 + 10 + 5 65

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2014

11. The Inah Burger restaurant chain uses a distribution center to prepare the food ingredients it provides its individual restaurants. The company is attempting to determine the location for new distribution center that will service five restaurants. The grid-map coordinates of the five restaurants and the annual numbers of 40-foot trailer trucks transported to each restaurant are as follows: Restaurants 1 2 3 4 5

X 100 210 250 300 400

Y 300 180 400 150 200

Annual Truck Shipments 30 25 15 20 18

Determine the coordinates of the location using the center-of-gravity method. a. (233, 242) c. (243, 231)

b. (236, 244) c. (245, 230)

Answer: a. (233, 242) X = (100(30) + 210(25) + 250(15) + 300(20) + 400(18)) / (30+25+15+20+18) X = 25200/108 X = 233.33 = 233 Y = (300(30) + 180(25) + 400(15) + 150(20) + 200(18)) / (30+25+15+20+18) Y = 26100/108 Y = 241.67 = 242 12. The Inah Burger restaurant chain in the previous problem i s considering three potential sites. With the following grid-map coordinates for its new distribution center: A(350, 300). B. (150, 250), and C (250, 300). Determine the best location using the load-distance formula. a. Site A, LD = 15,205 c. Site C, LD = 15,570

b. Site B, LD = 15,325 c. Site C, LD = 15,255

Answer: b. Site B, LD = 15,325 Site A: d1= = d2 = = d3 = = d4 = = d5 = = 76 | P a g e

2

2

(X1 – Xa) + (Y1 – Ya) 2

(100 – 350) + (300 - 300) 2

2

=

250

=

184.39

2

=

141.42

2

=

158.11

2

=

111.8

2

(X2 – Xa) + (Y2 – Ya) 2

2

(210 – 350) + (180 – 300) 2

2

(X3 – Xa) + (Y3 – Ya) 2

(250 – 350) + (400 – 300) 2

2

(X4 – Xa) + (Y4 – Ya) 2

(300 – 350) + (150 – 300) 2

2

(X5 – Xa) + (Y5 – Ya) 2

(400 – 350) + (300 – 300)


Site B: d1 = = d2 = = d3 = = d4 = = d5 = =

Site C: d1 = =

d2 = = d3 = =

d4 = = d5 = =

2

2

(X1 – Xa) + (Y1 – Yb) 2

(100 – 150) + (300 - 250) 2

2

=

70.71

=

92.20

2

=

180.28

2

=

180.28

2

=

254.95

=

150

2

=

126.49

2

=

100

2

=

158.11

2

=

180.28

2

(X2 – Xb) + (Y2 – Yb) 2

2

(210 – 150) + (180 – 250) 2

2

(X3 – Xb) + (Y3 – Yb) 2

(250 – 150) + (400 – 250) 2

2

(X4 – Xb) + (Y4 – Yb) 2

(300 – 150) + (150 – 250) 2

2

(X5 – Xb) + (Y5 – Yb) 2

(400 – 150) + (200 – 250) 2

2

(X1 – Xc) + (Y1 – Yc) 2

(100 – 350) + (300 - 300) 2

2

2

(X2 – Xc) + (Y2 – Yc) 2

(210 – 250) + (180 – 366) 2

2

(X3 – Xc) + (Y3 – Yc) 2

(250 – 250) + (400 – 300) 2

2

(X4 – Xc) + (Y4 – Yc) 2

(300 – 250) + (150 – 300) 2

2

(X5 – Xc) + (Y5 – Yc) 2

(400 – 250) + (200 – 300)

LD (Site A) = =

30(250) + 25(184.39) + 15(141.42) + 20(158.11) + 18(111.8) 19,405.65 = 19,406

LD (Site B) = =

30(70.71) + 25(92.20) + 15(180.28) + 20(180.28) + 18(254.95) 15,325.20 = 15,325

LD (Site C) = =

30(150) + 25(126.49) + 15(100) + 20(158.11) + 18(180.28) 15,569.49 = 15,570

77 | P a g e

2014


2014

13. Marla Homes, a home improvement/ building supply chain, is going to build a new warehouse facility to serve its stores in six Metro Manila Cities - Taguig, Pasig, Mandaluyong, Makati, Pasay, and Quezon City. The coordinates of this cities (in miles), using Manila, as the origin (0,0) of a set of coordinates, and the annual truck loads that supply each city as shown as follows. Determine the best site using the center- gravity technique. Pasig

Taguig

Mandaluyong

Makati

Pasay

X = 15 Y = 85 W = 160

X =42 Y = 145 W = 90

X = 88 Y = 145 W = 105

X = 125 Y = 140 W = 35

X = 135 Y = 125 W = 60

a. (77, 104) c. (79, 106)

Quezon City X = 180 Y = 18 W = 75

b. (80, 107) d. (81, 105)

Answer: c. (79, 106) X = 15(160) + 42(90) + 88(105) + 125(35) + 135(60) + 180(75) 160 + 90 + 105 + 35 + 60 + 75 = 78.85 = 79 Y = 85(160) + 145(90) + 145(105) + 140(35) + 125(60) + 18(75) 160 + 90 + 105 + 35 + 60 + 75 = 105.95 = 106 14. Refer to problem no. 13, Marla Homes base has two parcel of land, Site A & B in Metro Manila. Use the load-distance technique to determine which would be the best site with its load-distance value. Site A B

X 88 13

Y 80 127

a. Site A with LD = 38,986 c. Site B with LD = 44,121

b. Site A with LD = 40,391 d. Site B with LD = 43,542

Answer: b. Site A with LD = 40,391 For Site A: d Pasig

2

2

= 73.17

= (15 – 88) + (85 – 80)

d Taguig

= (42 – 88) + (145 – 80)

2

2

= 79.63

d Mandaluyong

= (88 – 88) + (145 – 80)

2

2

= 65.00

d Makati

= (125 – 88) + (140 – 80)

2

2

= 70.49

d Pasay

= (135 – 88) + (125 – 80)

2

2

= 65.07

d Quezon City

= (180 – 88) + (18 – 80)

For Site B: d Pasig d Taguig

78 | P a g e

2

2

2

= 110.94

2

= (15 – 13) + (85 – 127) 2

= 42.05 2

= (42 – 13) + (145 – 127)

= 34.13


2

2

d Mandaluyong

= (88 – 13) + (145 – 127)

d Makati

= (125 – 13) + (140 – 127)

2

2

= 112.75

d Pasay

= (135 – 13) + (125 – 127)

2

2

= 122.00

d Quezon City

= (180 – 13) + (18 – 127)

2

= 199.42

2014

= 77.13

2

Load Distance: For Site A: LD

= 160(73.17) + 90(79.63) + 105(65.00) + 35(70.49) + 60(65.07) + 75(110.94) = 40,390.75 = 40,391

For Site B: LD = 160(42.05) + 90(34.13) + 105(77.13) + 35(112.75) + 60(122.00) + 75(199.42) = 44,121.10 = 44,121 15. Roy Automobile Accessories, a manufacturer of automobile fan belts is considering three locations— Subic, Clark, and Laguna for a new plant. Cost studies indicate that fixed costs per year at the sites are P30,000.00, P60,000.00, and P110,000.00, respectively; and variable cost are P75.00 per unit, P45.00 per unit, and P25.00 per unit, respectively. The expected selling price of the f an belt produced is P120.00. The company wishes to find the most economical location for an expected volume of 2,000 units per year. a. Subic, P180,000.00 c. Clark, P150,000.00

b. Subic, P140,000.00 d. Laguna, P160,000.00

Answer: c. Clark, P150,000.00 For Subic, Total Cost = P30,000.00 + P75.00(2,000) = P180,000.00 For Clark, Total Cost = P60,000.00 + P45.00(2,000) = P150,000.00 For Laguna, Total Cost = P110,000.00 + P25.00(2000) = P160,000.00 With an expected volume of 2,000 units per year, Clark provides the lowest cost l ocation. 16. A plastic firm has four work centers (A, B, C, and D) in series with individual capacities (units per day) and actual output as shown.

A 450

B 390

C 360

D 400

actual output = 306/ day

What is the process capacity? a. 306 c. 450

b. 360 d. 1,600

Answer: b. 360 Process Capacity = capacity of most limited component in the line = 360 units/ day

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2014

17. Refer to Problem no. 16, what is the process efficiency? a. 19% c. 68%

b. 22.5% d. 85%

Answer: d. 85% Process Efficiency = actual output/ process capacity = 306/ 360 = 85% 18. Dennis Furniture Company manufactures four-drawer oak cabinets in six stages. In the first stage, the boards forming the walls of the cabinets are cut; in the second stage the front drawer panels are woodworked; in the third stage the boards are sanded and finished; in the fourth stage the boards are cleaned, stained, and painted with a clear finish; in the fifth stage the hardware for pulls, runners, and fittings is installed; and in the final stage the cabinets are assembled. Inspection occurs at each stage of the process, and the average percentages of good-quality units are as follows: Stage 1 2 3 4 5 6

Average Percentage Good Quality 87% 91% 94% 93% 93% 96%

The cabinets are produced in weekly production runs with a product input for 300 units. Determine the weekly product yield of good-quality cabinets. a. 186 c. 312

b. 288 d. 486

Answer: a. 186 O =

(300)(0.87)(0.91)(0.94)(0.93)(0.93)(0.96) = 185.3 = 186

19. Refer to problem no. 18, what would weekly product input have to be in order to achieve a final weekly product yield of 300 cabinets? a. 186 c. 312 Answer: d. 486 I = I =

300 / (0.87)(0.91)(0.94)(0.93)(0.93)(0.96) 485.5 = 486

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b. 288 d. 486


2014

20. The Jelo Motor Company, motors are produced in a three-stage process. Motors are inspected following each stage with percentage yields of good quality in process units as follows: Stage 1

Average Percentage Good Quality 0.96

2

0.98

3

0.95

The company wants to know the daily product yield for product input of 250 units per day. a. 263 c. 223

b. 238 d. 280

Answer: c. 223 O = O =

(250)(0.96)(0.98)(0.95) 223.44 = 224

21. Refer to problem no. 20, how many input units it would have to start with each day to result in a final daily yield of 250 good quality units? a. 263 c. 223

b. 238 d. 280

Answer: d. 280 I = I =

250 / (0.96)(0.98)(0.95) 279.72 motors = 280

22. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000 stov es if the good quality of each stov e is 88%? a. 13,200 c. 125,000

b. 1,800 d. 17,045

Answer: d. I = I = I =

O/(1 - P) 15,000/(1 - 0.12) 17,045.45 = 17,045

23. Lara Company operates a small telephone order system for a catalog of its clothing products. The catalog orders are processed in four stages. Errors can be made i n orders at any of these stages, and the average percentages of errors that occur at each stage are as follows. Stage 1 2 3 4

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%Error 19% 16% 10% 8%


2014

If an average of 460 telephone orders is processed each day, how many errorless orders will result? a. 112 c. 244

b. 259 d. 129

Answer: b. 259 O = O = O =

460 (1 - 0.19)(1 - 0.16)(1 - 0.10)(1 - 0.08) 460(0.81)(0.84)(0.90)(0.92) 259.15 = 259

24. Liam Manufacturing Company has a weekly product input of 2,800 units. The average percentage of good-quality product is 87 percent. Of the poor quality products 60 percent can be reworked and sold as good-quality products. Determine the weekly product output? a. 2,654 c. 1,462

b. 5,364 d. 3,218

Answer: 2,654 O = O = O =

2,800(0.87) + 2,800(0.13)(0.60) 2,436 + 218.4 2,654.4 = 2,654

25. Assume that production volume is 1,600 pieces per day, the standard time is 0.004 hour per piece, 8 working hours per day, setup time at 0.2 hr per day, and scrap rate of 0.10. Find the fractional machine number. a. 1.12 c. 0.91

b. 0.85 d. 1.21

Answer: c. 0.91 F = [(1600)/0.90](0.004)/ (8 – 0.2) = 0.91 26. A product requires two sequential machine operations. The first takes 3.5 minutes and the defect percentage is 12. The second takes 6.0 minutes and the defect percentage is 7. In another similar plant belonging to the same company, past annual data on identical operations and working conditions indicate that a total of 2,198 hours due to set up of machines and 2,052 hours due to machine unavailability due to maintenance per year. Assuming 250 work days per year and a daily shift of 10 hours, it is desired to determine the minimum fractional number of machines to manufacture 50,000 units per year. a. 4 c. 6

b. 5 d. 7

Answer: b. 5 P2 = 50,000/0.93 = 53,763.44 P1 = 53,763.44/0.88 = 61,094.82 F = ((53,763.44)(6) + (61094.82)(3.5))/(60*250*10)(2,198/2,500)(2,052/2,500)) = 5

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27. Eric Explosives Company is considering the expansion of a solid-propellant manufacturing process by adding more 1-ton capacity curing furnaces. Each batch (1 ton) of propellant must undergo 30 minutes of furnace time, including load and unload operations. However, the furnace is used only 80 percent of the time due to power restrictions in the other parts of the system. The required output for the new layout i s to be 16 tons per shift (8 hours). Plant (system) efficiency is estimated at 50 percent of system capacity. Determine the number of furnaces required. a. 3 c. 1

b. 4 d. 5

Answer: a. 3 F = 30 mins per ton x 16 tons per shift/ 8 x 60 x 0.50 x 0.80 = 480/ 192 = 2.5 = 3 28. Refer to problem no. 27, estimate the percentage of time the f urnaces will be idled. a. 20% c. 33%

b. 25% d. 67%

Answer: d. 67% Percentage of Idle Time: Total hours available per shift = 3 furnaces @ 8 hours Total hours of actual use per shift = 16 tons (0.5 hr/ ton) Idle Time Percentage of Idle Time = 16 hours idle/ 24 hours total

= 24 furnace hours = 8 furnace hours = 16 hours = 67% idle time

29. Charmz Developing Agency must determine how many photo-enlarger cubicles are required to maintain an output of 200 good prints per hour. The set-up and exposure time can theoretically be done in 2 minutes per print, but operators are on the average only 90 percent efficient and, in addition, 5 percent of the prints must be scrapped and redone. Also, the cubicles can be utilized for enlarging only 70 percent of the time. What is the required process capacity in prints per hour? a. 212 c. 211

b. 250 d. 200

Answer: c. 211 Required process capacity = good output/ process efficiency = 200/ 0.95 = 211 prints/ hr 30. Refer to problem no. 29, what average output per hour can be expected f rom each cubicle, taking its use factor and efficiency into account? a. 211 c. 19

b. 30 d. 200

Answer: c. 19 Output/ hr = (unit capacity) (utilization) (efficiency) Where unit capacity = 60 mins/ hr/ 2 mins/ print = 30 prints/ hr Output/ hr = (30 prints/ hr) (0.70) (0.90) = 18.9 prints/ hr = 19 31. Refer to problem no. 29, how many enlarger cubicles are required? a. 14 c. 16 83 | P a g e

b. 10 d. 12


2014

Answer: d. 12 Number of cubicles = 210.5 prints/ hr required/ 18.9 prints/ hr-cubicle = 11.4 or 12 cubicles 32. Dason Plastics manufacturer must acquire some molding machines capable of producing 160,000 good parts per year. They will be installed in a production line that normally produces 20 percent rejects because of the tight aerospace specifications. Assume that it takes 90 seconds to mold each part and the plant operates 2,000 hours per year. If the molding machines are used only 50 percent of the time and are 90 percent efficient, what actual (usable) molding machine output per hour would be achieved? a. 40 c. 45

b. 18 d. 20

Answer: b. 18 Output/ hr Where, unit capacity Output/ hr

= (unit capacity) (utilization) (efficiency) = 60 mins/ hr/ 1.5 mins/ part = 40 parts/ hr = (40 parts/ hr) (0.50) (0.90) = 18 parts/ hr

33. Refer to problem no. 32, how many molding machines would be required? a. 4 c. 6

b. 8 d. 12

Answer: c. 6 Number of Molding Machines

= (160,000/ 0.80)(1.5)/ (2000)(60)(0.50)(0.90) = 300,000/ 54,000 = 5.56 = 6 machines

34. Given: Year 1 2 3 4 5

Demand (units) 220,000 275,000 380,000 420,000 565,000

% Scrap: 3% Standard Time: 2 minutes per unit Target Machine Efficiency: 90% Machine Breakdown: 30 minutes per day Operation Schedule: 8am – 4pm daily schedule/ 20 working days per month How many machines you will acquire/ buy on Year 1? a. 5 c. 2 Answer: a. 5

84 | P a g e

b. 7 d. 9


Given:

H = 480 E = 0.85 R = 480-30 = 450/480 = 0.9375 T = 2 mins per unit O1 = 220,000 per year O2 = 275,000 per year O3 = 380,000 per year O4 = 420,000 per year O5 = 565,000 per year P = 3%

Solution: Q1 = 220,000/ (1 – 0.03) = /12 = /20 = 945.017 per day Q2 = 275,000/ (1 – 0.03) = /12 = /20 = 1,181.271 per day Q3 = 380,000/ (1 – 0.03) = /12 = /20 = 1,632.302 per day Q4 = 420,000/ (1 – 0.03) = /12 = /20 = 1,804.124 per day Q5 = 565,000/ (1 – 0.03) = /12 = /20 = 2,426.976 per day HER = 480 x 0.85 x 0.9375 = 382.5 F1 = 945.017 x 2 = 4.9 = 5 machines 382.5 35. Refer to problem 34, how many machines you will acquire/ buy on Year 2? a. 5 c. 1

b. 7 d. 9

Answer: c. 1 F1 = 945.017 x 2 = 4.9 = 5 machines 382.5 F2 = 1,181.271 x 2 = 6.2 = 6 machines 382.5 Therefore, buy only 2 machines (6 – 5 = 1) in year 2 36. Refer to problem no. 34, how many machines you will acquire/ buy on Year 3? a. 5 c. 3

b. 7 d. 9

Answer: c. 3 F2 = 1,181.271 x 2 = 6.2 = 6 machines 382.5 F3 = 1,632.302 x 2 = 8.5 = 9 machines 382.5 Therefore, buy only 2 machines (9 – 6 = 3) in year 3 37. Refer to problem no. 34, how many machines you will acquire/ buy on Year 4? a. 1 c. 2 Answer: a. 1

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b. 10 d. 9

2014


2014

F3 = 1,632.302 x 2 = 8.5 = 9 machines 382.5 F4 = 1,804.124 x 2 = 9.4 = 10 machines 382.5 Therefore, buy only 1 machine (10 – 9 = 1) in year 4 38. Refer to problem no. 34, how many machines you will acquire/ buy on Year 5? a. 1 c. 3

b. 10 d. 13

Answer: c. 3 F4 = 1,804.124 x 2 = 9.4 = 10 machines 382.5 F5 = 2,426.976 x 2 = 12.7 = 13 machines 382.5 Therefore, buy only 3 machines (13 – 10 = 3) in year 5 39. A team of Industrial Engineers conducted a work sampling of identical machines being used for a manufacturing company and they have observed the following: % Idleness Machine 1 20% Machine 2 35% Machine 3 15% Machine 4 55% The machines are running based on the schedule of operation per shift. Shift Schedule: 6am – 2pm/ 2pm – 10pm/ 10pm – 6am Break Time: 1-hr meal break and 15 minutes coffee or short break per shift. Compute for the number of machines required in a given shift. a. 1 c. 3

b. 2 d. 4

Answer: c. 3 SQ = 405 (0.80) + 405 (0.65) + 405(0.85) + 405(0.45) = 1113.75 minutes E = not given so considered 1 R = not given so considered 1 H = 8 x 60 = 480 – 60 –15 = 405 per shift F = 1113.75/ 405 = 2.75 = 3 machines 40. Mandy Garments produces T-shirts for road races. They need to acquire some new stamping machines to produce 30,000 good T-shirts per month. Their plant operates 200 hours per month, but the new machines will be used for T-shirts only 60 percent of the time and the output usually includes 5 percent that are ―seconds‖ and unusable. The stamping operation takes 1 minute per T-shirt, and the stamping machines are expected to have 90 percent efficiency when considering adjustments, changeover of patterns, and unavoidable downtime. How many machines are required? a. 5 c. 7 Answer: a. 5

86 | P a g e

b. 6 d. 8


Number of stamping machines

2014

= (30,000/ 0.95)(1 minute/ T-shirt)/ (200)(60)(0.60)(0.90) = 31,578.95/ 6480 = 4.9 = 5 machines

41. During one-8-hour shift, 770 non-defective parts are desired from a fabrication operation. The standard time for the operation is 12 minutes. Because the machine operators are unskilled, the actual time it takes to perform the operation is 25 mi nutes and, on the average, one-sixth of the parts that begin fabrication are scrapped. Assuming that each of the machines used for this operation will not be available for 45 minutes each shift and there is a probability of 0.05 that each machine will breakdown, determine the number of machines required. a. 50 c. 54

b. 52 d. 56

Answer: d. 56 S = 12 mins. E = 12/25 = 0.48 R = 1 – 0.05 = 0.95 H = 480 – 45 = 453 mins. P = 1/6 = 0.167 Q= 770 = 924 Parts 1 – 0.167 Solution: F = SQ = 12 x 924 HER 435 x 0.48 x 0.95

= 55.90 = 56 machines

42. Nestor Briefcases is an exclusive producer of handcrafted, stylish cases. Priding itself on its earlier reputation, the company assembles each case with care and attention to detail. This laborious process requires the completion of six primary work elements, which are listed here. Work Element A Tan leather B Dye leather C Shape case D Mold hinges and fixtures E Install hinges and fixtures F Assemble case

Precedence A B C, D E

Time (min) 30 15 10 5 10 10

If the demand is 50 cases per 40-hour week, compute the cycle time for the process. a. 30 c. 46 Answer: d. 48

87 | P a g e

b. 40 d. 48


30

15

10

A

B

C

D

E

F

5

10

10

Cycle time=

total working hours

=

(40 hours x 60 minutes/hour)

desired units of output

= 48 minutes

(50 cases)

43. Refer to problem no. 42, compute the lead time required for assembling one briefcase. a. 30 c. 80

b. 48 d. 45

Answer: c. 80 Lead time= (30 + 15 + 10 + 5 + 10 + 10) = 80 minutes 44. Refer to problem no. 42, calculate the theoretical minimum number of workstations. a. 3 c. 4

b. 2 d. 1

Answer: b. 2 N=

lead time

=

cycle time

(30 + 15 + 10 + 5 + 10 + 10)

= 1.66 ≈ 2 workstations

48


45

AD

BCEF

45

35

AB

CDEF

b.

88 | P a g e

2014


2014

c. 30

30

A

BCD

30

25

A

BC

20

EF

d. 25

DEF

Answer: b

Task A B C D E F

45

35

AB

CDEF

Time 30 15 10 5 10 10

Number of Followers 4 3 2 2 1 0

Station 1 A (48 – 30 = 18) B (18 – 15 = 3)

ST1 = 45 mins

Station 2 C (48 – 10 = 38) D (38 – 5 = 33) E (33 – 10 = 23) F (23 – 10 = 13) ST2 = 35 mins

46. Refer to problem no. 42, compute the line’s efficiency. a. 89% c. 81%

b. 83% d. 93%

Answer: b. 83% Efficiency =

lead time

=

(30 + 15 + 10 + 5 + 10 + 10)

no. of workstations x cycle time

= 83.33%

2(48)

47. Refer to problem no. 42, suppose the demand for briefcases increases to 80 cases per week. Calculate a new cycle time. a. 30 c. 50 Answer: a. 30 89 | P a g e

b. 35 d. 45


Cycle time =

total working hours

=

(5 days x 8 hours/day x 60 minutes/hour)


(80 cases)

48. Refer to problem no. 47, bal ance the line based on the l ongest task time a. 35

45

AD

BCEF

45

35

AB

CDEF

30

30

A

BCD

30

25

A

BC

b.

c. 20

EF

d. 25

DEF

Answer: c

Task A B C D E F

30

30

A

BCD

Time 30 15 10 5 10 10

90 | P a g e

Rank 1 2 3 6 4 5

20

EF

2014

= 30 minutes


Station 1 A (30 – 30 = 0)

Station 2 B (30 – 15 = 15) C (15 – 10 = 5) D (5 – 5 = 0) ST2 = 30 mins

ST1 = 30 mins

2014

Station 3 E (30 – 10 = 20) F (20 – 10 = 10) ST3 = 20 mins

49. Refer to problem no. 47, calculate the new efficiency of the manufacturing process. a. 89% c. 81%

b. 83% d. 93%

Answer: a. 89% lead time

Efficiency =

=

(30 + 15 + 10 + 5 + 10 + 10)


= 88.89%

3(30)


b. 2 d. 1

Answer: a. 3 lead time

N=

=

(30 + 15 + 10 + 5 + 10 + 10)

cycle time


30

51. Pepper & Mys Bakeshop has set a production quota of 600 party cakes per 40-hour workweek. Use the following information to compute for the cycle time. Predecessor Work Element A B A C B D A, E E F C, D

Performance Time (min) 1 2 2 4 3 4

a. 3 c. 4

b. 16 d. 13

Answer: c. 4 1

2

2

A

B

C F

E

D

3

4

91 | P a g e

4


total working hours

Cycle time=

=



= 4 minutes

(600 party cakes)

52. Refer to problem no. 51, compute the theoretical minimum number of workstations. a. 5 c. 2

b. 3 d. 4

Answer: d. 4 lead time

N=

=

(1 + 2 + 2 + 4 + 3 + 4)

cycle time

= 4 workstations

4

53. Refer to problem no. 51, balance the line using incremental utilization method a. 3

AB

3.25

CDEF

3.25

CDEF

3.25

CDEF

b. 2.5

ABC

2.5

5.5

5.5

ABC

DEF

DEF

3.25

3.25

3.25

c. 3

AB

CEDF

C ED F

CEDF

3.25

C ED F

d. 3.0

AB

3.0

AB

3.25

C ED F

3.25

CEDF

3.25

CEDF

Answer: c 3

AB

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3.25

CEDF

3.25

C ED F

3.25

CEDF

3.25

C ED F

2014


2014

Based on Incremental Utilization Method (IUM) WS 1 1 1 2 2 2 2

Task A A, B A, B, C C C,E C, E, D C, E, D, F

Task Time 1 1+2=3 3+2=5 2 2+3=5 5+4=9 9 + 4 = 13

# of WS’s 1/ 4 = 0.25 = 1 3/ 4 = 0.75 = 1 5/ 4 = 1.25 = 2 2/ 4 = 0.50 = 1 5/ 4 = 1.25 = 2 9/ 4 = 2.25 = 3 13/ 4 = 3.25 = 4

Incremental Utilization 25% 75% 62.5% 50% 62.5% 75% 81%

54. Refer to problem no. 51, calculate the efficiency of the assembly line. a. 95% c. 80%

b. 90% d. 83%

Answer: c. 80% lead time

Efficiency =

=

(1 + 2 + 2 + 4 + 3 + 4)


= 80%

5(4)

55. The Hanzel Pizza is revamping its order processing and pizza-making procedures. In order to deliver fresh pizza fast, six elements must be completed. Work Element

Precedence

A Receive order B Shape dough C Prepare toppings D Assemble pizza E Bake pizza F Deliver pizza

A A B, C D E

Time (min) 2 1 2 3 3 3

If the demand is 120 pizzas per night (5:00 p.m. to 1:00 a.m.), compute the cycle time for the process. a. 4 c. 14

b. 3 d. 13

Answer: a. 4 2

1

3

3

3

A

B

D

E

F

C 2

Cycle time =

total working hours desired units of output

93 | P a g e

=

(8 hours x 60 minutes/hour) (120 pizzas)

= 4 minutes


56. Refer to problem no. 55, compute the lead time for the process. a. 4 c. 14

b. 3 d. 13

Answer: c. 14 Lead time= (2 + 1 + 2 + 3 + 3 + 3) = 14 minutes 57. Refer to problem no. 55, Calculate the theoretical minimum number of workstations. a. 2 c. 4

b. 3 d. 5

Answer: c. 4 N=

lead time

=

cycle time

(2 + 1 + 2 + 3 + 3 + 3)


4

58. Refer to problem no. 55, bal ance the line using the most number of followers method. a. 3

5

3

3

AB

CD

E

F

3

2

3

3

3

AB

C

D

E

F

4

1

3

3

3

AC

B

D

E

F

4

4

3

3

AC

BD

E

F

b.

c.

d.

94 | P a g e

2014


2014

Answer: d

Task A B C D E F

4

4

3

3

AC

BD

E

F

Time 2 1 2 3 3 3

Number of Followers 5 3 3 2 1 0

Station 1 A (4 – 2 = 2) C (2 – 2 = 0) ST1 = 4 mins

Station 2 B (4 – 1 = 3) D (3 – 3 = 0) ST2 = 4 mins

Station 3 E (4 – 3 = 1)

Station 4 F (4 – 3 = 1)

ST3 = 3 mins

ST4 = 3 mins

59. Refer to problem no. 55, compute the efficiency of the line. a. 88% c. 89%

b. 91% d. 93%


Efficiency =

=

(2 + 1 + 2 + 3 + 3 + 3)


= 87.5%

4(4)

60. Refer to problem no. 55, suppose demand increases to 160 pizzas per night. What is the new cycle time? a. 4 c. 14

b. 3 d. 13

Answer: b. 3 1

B 2

3

3

3

A

D

E

F

C 2

Cycle time =


95 | P a g e

=

(8 hours x 60 minutes/hour) (160 pizzas)

= 3 minutes


2014

61. Refer to problem no. 60, balance the line based on the l ongest task time method. a. 3

5

3

3

AB

CD

E

F

3

2

3

3

3

AB

C

D

E

F

4

1

3

3

3

AC

B

D

E

F

4

4

3

3

AC

BD

E

F

b.

c.

d.

Answer: b

Task A B C D E F

3

2

3

3

3

AB

C

D

E

F

Time 2 1 2 3 3 3

Station 1 A (3 – 2 = 1) B (1 – 1 = 0) ST1 = 3 mins

Rank 4 6 5 1 2 3 Station 2 C (3 – 2 = 1)

Station 3 D (3 – 3 = 0)

Station 4 E (3 – 3 = 0)

Station 5 F (3 – 3 = 0)

ST2 = 2 mins

ST3 = 3 Mins

ST4 = 3 mins

ST5 = 3 mins

62. Refer to problem no. 60, calculate the new theoretical minimum number of workstations. a. 2 c. 4 96 | P a g e

b. 3 d. 5


2014

Answer: d. 5 lead time

N=

=

(2 + 1 + 2 + 3 + 3 + 3)

cycle time


3

63. Neren’s Eye Care, Inc., is a full-service optical supplier that sells eyeglasses, contact lenses, protective eye apparel to opticians. Bogs’ job is to assemble custom-ordered lenses into eyeglasses for customers. Sales have been good lately, and Bogs has been assembling 100 glasses a day. The manager of Neren’s asked Bogs to write down the precedence requirements and approximate assembly times for each step in the assembly process. The data are shown here. Element Description

Precedence

A

-

Time (min) 1.0

A B B C, D

1.0 0.4 0.4 2.0

Inspect right and left lens for scratches and proper match Pop lens into frame Position right side piece and attach to frame Position left side piece and attach to frame Package

B C D E

Assuming an 8-hour workday, how long does it take Bogs to assemble one pair of glasses? a. 2 c. 4

b. 2.4 d. 4.8

Answer: d. 4.8 0.4

C 1

1

A

B

E 2

D 0.4

Cycle time =

total working hours

=



= 4.8 minutes

(100 eyeglasses)

Lead time = (1 + 1 + 0.4 + 0.4 + 2) = 4.8 minutes 64. Refer to problem no. 63, Neren’s anticipates a surge in demand with the opening of its own retail outlets. If the assembly process is set up as an assembly line, what is the maximum number of eyeglasses that can be assembled in one day, regardless of the number of workers hired? a. 200 c. 100

b. 240 d. 480

Answer: b. 240 Maximum eyeglasses/day =

(4.8 minutes x 100 eyeglasses) 2 minutes

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= 240 eyeglasses


1

1.8

A

BCD

2014

2

E

With maximum time in a workstation of 2 minutes it can produce 240 eyeglasses with 3 workers 65. Refer to problem no. 64, what is the efficiency of the line? a. 80% c. 100%

b. 91% d. 95%


Efficiency =

=

(1 + 1 + 0.4 + 0.4 + 2)


= 80%

3(2)

66. Prof. Jone has assigned 15 cases in his Seminar class to be completed in a 15 week semester. The students, of course, are moaning and groaning that the caseload cannot possibly be completed in the time allotted. Prof. Jone sympathetically suggests that the students work in groups and learn to organize their work efficiently. Knowing when a situation is hopeless, the students make a list of the tasks that have to be completed in preparing a case. These tasks are listed here, along with precedence requirements and estimated time in days. Assuming students will work 5 days a week on this assignment, how many students should be assigned to each group? Element Description

Precedence

Time (days)

A b c d e f

a a b d c, e

1 4 3 1 4 4

Read case Gather data Search literature Load in data Run computer analysis Write/type case a. 3 c. 5

b. 4 d. 6

Answer: b. 4 4

1

4

B

D

E

1

A

Cycle time =

C

F

3

4


98 | P a g e

=

(15 weeks x 5 days) (15 cases)

= 5 days


lead time

N=

=

(1 + 4 + 3 + 1 + 4 + 4)

cycle time

2014

= 3.4 ≈ 4 workstations or students

5

67. The precedence diagram and task times (in minutes) for assembling Reyson’s Stamp Pad are shown here. Set up an assembly line to produce 125 stamp pads in a 40-hour week. What is the cycle time? 8

5

A

B

F

C

D

E

6

10

2

J

4

H

G

K

7

3

I

5

a. 10 c. 61

9

b. 19.2 d. 2

Answer: b. 19.2 Cycle time =

total working hours

=



= 19.2 minutes

(125 stamp pads)


19

11

12

ABC

DFG

EH I

JK

19

19

18

5

ACB

DGF

EHJ

IK

19

17

13

12

ABC

DEG

FHI

JK

b.

c.

99 | P a g e


2014

d. 19

16

14

12

ACB

DFE

GH I

JK

19

19

18

5

ACB

DGF

EHJ

IK

Answer: b.

Task

Time

A B C D E F G H I J K

Number of Followers

8 5 6 10 2 4 5 7 2 9 3

7 6 6 5 4 4 4 3 1 1 0

Station 1 A (19.2 – 8 = 11.2) C (11.2 – 6 = 5.2) B (5.2 – 5 = 0.2) ST1 = 19.0

Rank 1 3 2 4 7 6 5 8 10 9 11

Station 2 D (19.2 – 10 = 9.2) G (9.2 – 5 = 4.2) F (4.2 – 4 = 0.2) ST2 = 19.0

Station 3 E (19.2 – 2 = 17.2) H (17.2 – 7 = 10.2) J (10.2 – 9 = 1.2) ST3 = 18

Station 4 I (19.2 – 2 = 17.2) K (17.2 – 3 = 14.2) ST4 = 5

69. The work elements, precedence requirements, and time requirements to assemble a picture frame are shown here. What is the cycle time capable of producing 1,600 frames per 40-hour week? Element Description

Precedence

A B C D E F G H I

A, B C, D E, F F, G D

Attach left frame side to top of frame Attach right frame side to bottom of frame Attach left and right frame subassemblies Cut 8-inch x 10-inch glass Cut 8-inch x 10-inch cardboard Place glass into frame Place cardboard into frame Secure cardboard and glass Apply descriptive label to glass a. 1.5 c. 0.10

Answer: a. 1.5

100 | P a g e

b. 0.70 d. 3.4

Time (min) 0.35 0.35 0.70 0.50 0.50 0.20 0.20 0.50 0.10


2014

.10

I .35

.50

A

D .20

C

F

H

.50

.70

B

E

.35

.50

G .20

Cycle time =


=


= 1.5 minutes

(1600 frames)

70. Refer to problem no. 69, balance the assembly line based on the computed cycle time using incremental utilization method a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

CEF

0.70

GH

c. 1.40

ABC

1.40

DEFG

0.60

HI

d. 1.45

DE AI

Answer: c

101 | P a g e

1.45

BCFG

0.50

H


1.40

1.40

ABC

DEFG

2014

0.60

HI

Based on Incremental Utilization Method (IUM) WS 1 1 1 1 2 2 2 2 2 3 3

Task A A, B A, B, C A, B, C, D D D, E D, E, F D, E, F, G D, E, F, G, H H H, I

Task Time 0.35 0.35 + 0.35 = 0.70 0.70 + 0.70 = 1.40 1.40 + 0.50 = 1.90 0.50 0.50 + 0.50 = 1.00 1.00 + 0.20 = 1.20 1.20 + 0.20 = 1.40 1.40 + 0.50 = 1.90 0.50 0.50 + 0.10 = 0.60

# of WS’s 0.35/ 1.50 = 0.23 = 1 0.70/ 1.50 = 0.47 = 1 1.40/ 1.50 = 0.93 = 1 1.90/ 1.50 = 1.27 = 2 0.50/ 1.50 = 0.33 = 1 1.00/ 1.50 = 0.67 = 1 1.20/ 1.50 = 0.80 = 1 1.40/ 1.50 = 0.93 = 1 1.90/ 1.50 = 1.27 = 2 0.50/ 1.50 = 0.33 = 1 0.60/ 1.50 = 0.40 = 1

Incremental Util 23% 47% 93% 63% 33% 67% 80% 93% 63% 33% 40%

Effective CT = 1.40 71. Refer to Problem No. 70, what is the maximum output per week? a. 1,600 c. 1,750

b. 1,715 d. 1,656

Answer: b. 1,715 Maximum Output per Week =

2,400 mins per week -----------------------------1.40

= 1,715 units/ week

72. Refer to problem no. 69, balance the assembly line based on the computed cycle time using most number of followers method. a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

102 | P a g e

CEF

0.70

GH


c. 1.40

1.40

ABC

DEFG

0.60

HI

d. 1.45

1.45

DE AI

BCFG

0.50

H

Answer: b Based on the Most Number of Task Followers: Task A B D C E F G H I

Time 0.35 0.35 0.70 0.50 0.50 0.20 0.20 0.50 0.10

Station 1 D (1.50 – 0.50 = 1.00) A (1.00 – 0.35 = 0.65) B (0.65 – 0.35 = 0.30) I (0.30 – 0.10 = 0.20) ST = 1.5 – 0.20 = 1.30

No. of Task Followers 4 4 4 3 2 2 1 0 0

Rank 2 3 1 4 5 6 7 8 9

Station 2 Station 3 C (1.50 – 0.70 = 0.80) G (1.5 – 0.20 = 1.30) E (0.80 – 0.50 = 0.30) H (1.3 – 0.50 = 0.80) F (0.30 – 0.20 = 0.10) ST = 1.5 – 0.10 = 1.40 ST = 1.5 – 0.80 = 0.70

Effective CT = 1.40

1.30

DAB I

1.40

CEF

0.70

GH


b. 1,715 d. 1,656

Answer: b. 1,715 Maximum Output per Week =

103 | P a g e

2,400 mins per week -----------------------------1.40

= 1,715 units/ week

2014


2014

74. Refer to problem no. 69, balance the assembly line based on the computed cycle time using longest task time method. a. 1.4

1.2

.80

ABC

DEG

FIH

1.30

1.40

b.

DAB I

CEF

0.70

GH

c. 1.40

1.40

ABC

DEFG

0.60

HI

d. 1.45

1.45

DE AI

BCFG

0.50

H

Answer: d Based on the Longest Task Time Task A B C D E F G H I

Task Time (min) 0.35 0.35 0.70 0.50 0.50 0.20 0.20 0.50 0.10

Station 1 D (1.50 – 0.50 = 1.00) E (1.00 – 0.50 = 0.50) A (0.50 – 0.35 = 0.15) I (0.15 – 0.10 = 0.05) ST = 1.5 – 0.05 = 1.45 Effective CT = 1.45 104 | P a g e

Rank 5 6 1 2 3 7 8 4 9

Station 2 Station 3 B (1.50 – 0.35 = 1.15) H (1.5 – 0.50 = 1.00) C (1.15 – 0.70 = 0.45) F (0.45 – 0.20 = 0.25) G (0.25 – 0.20 = 0.05) ST = 1.5 – 0.05 = 1.45 ST = 1.5 – 1.00 = 0.50


1.45

1.45

DE AI

2014

0.50

BCFG

H


b. 1,715 d. 1,656

Answer: d. 1,656 Maximum Output per Week =

2,400 mins per week -----------------------------1.45

= 1,656 units/ week

76. Refer t o problem no. 69, calculate the m aximum number of frames that can be assembles each week. a. 2,557 c. 3,567

b. 2,452 d. 3,429

Answer: d. 3,429 Number of frames(in a week) =

5 days

x

week

8 hours

x

day

60 minutes hour

x

1 frame

= 3428.57 ≈ 3429

0.70min

77. Refer to problem no. 76, rebalance the line for maximum production. Assuming one worker per workstation. How many workers would be required? a. 5 c. 6

b. 4 d. 3

Answer: a. 5 Cycle time =

total working hours

=

(40 hours x 60 m inutes/hour)


= 0.7 minutes

(3428 frames)

Lead time = (0.35 + 0.35 + 0.70 + 0.50 + 0.50 + 0.20 + 0.20 + 0.50 + 0.10) = 3.4 minutes N=

lead time

=

cycle time

3.4

= 4.86 ≈ 5 workers

0.7

78. Refer to problem no. 76, assume the company can sell as many frames as can be produced. If workers are paid P60.00 an hour. What is the total cost per frame? a. 1.67 c. 6.17

b. 1.47 d. 7.14

Answer: d. 7.14 Cost per worker =

3428 frame week

105 | P a g e

x

1 week 5 day

x

1 day 8 hour

x

1 hour P60.00

= P1.42833 / worker


2014

Total cost = P1.42833 x 5 workers = P7.14 / frame 79. The Racela Finance Corporation has set a processing quota of 80 insurance claims per 8-hour day. The claims process consists of five elements, which are detailed in the following table. Racela has decided to use an assembly line arrangement to process the forms and would like to make sure they have set up the line in the most efficient fashion. Calculate the cycle time required to meet the processing quota. Element Precedence A B A C B D A E C, D

Performance Time (min) 4 5 2 1 3

a. 5 c. 15

b. 6 d. 16

Answer: b. 6 4

5

2

A

B

C 3

E D 1

total working hours

Cycle time =


=


= 6 minutes

(80 insurance claims)

80. Refer to problem no. 79, determine how many claims can actually be processed on your line. a. 60/ day c. 80/ day

b. 70/ day d. 90/ day

Answer: c. 80/ day No. of claims =

8 hour day

106 | P a g e

x

60 minutes _1 claim x = 80 / day hour 6 minute


2014

81. A firm must produce 40 units/day during an 8-hour workday. Tasks, tim es, and predecessor activities are given below. Task A B C D E F G H Total

Time (Minutes) 2 2 8 6 3 10 4 3 38 minutes

Predecessor(s) A C B D, E F G

Determine the cycle time to produce the 40 units per day. a. 10 c. 12

b. 38 d. 20

Answer: c. 12 Cycle Time = 8 hrs x 60 mins/hr = 480 = 12 minutes 40 units 40 82. Thomas Santos, manager of a metropolitan branch office of the state department of motor vehicles, attempted to perform an analysis of the driver ’s license renewal operations. He identified the steps and associated times required to perform each step as follows: Job A. Review renewal application for correctness B. Process and record payment C. Check file violations and restrictions D. Conduct eye test E. Photograph applicant F. Issue temporary license

Average Time to perform (seconds) 15 30 60 40 20 30

Santos found that each step was assigned to a different person. Santos also found that jobs A, B, C, and D were handled by general clerks who were each paid P270.00 per hour. Job E was by a photographer paid P360.00 per hour. Job F, the issuing of temporary licenses, was required by state policy to be handled by a uniformed motor vehicle officer. Officers were paid P405.00 per hour, but they could be assigned to any j ob except photography. A review of the jobs indicated that job A, reviewing the application for correctness, had to be performed before any other step could be taken. Similarly, job F, issuing the temporary license, could not be performed until all the other steps were completed. The checking of file violations and restrictions could be performed while the applicant is having his eye test. The branch offices were charged P450.00 per hour for each camera to perform photography. Determine the maximum number of applications per hour that can be handled by the present configuration of the process? a. 60 c. 120 Answer: a. 60

107 | P a g e

b. 90 d. 180


2014

60 C

15

A

30

20

30

B

E

F

D

40 CT = 60 seconds Max. no. of application per hour = 3,600 = 60 applications per hour 60 83. Refer to problem no. 82, how many applications can be processed per hour if a second clerk is added to check for violations? a. 60 c. 120

b. 90 d. 180

Answer: b. 90 30 15

A

C

30

20

30

B

E

F

D

40

CT = 40 seconds Max. no. of applications per hour = 3,600 = 90 applications per hour 40 84. In addition to problem no. 83, assuming one more clerk is added to job D, what is the maximum number of applications the process can handle? a. 60 c. 120 Answer: c. 120

108 | P a g e

b. 90 d. 180


2014

30 C

15

A

30

20

30

B

E

F

D

20 CT = 30 seconds Max. no. of applications per hour = 3,600 = 120 applications per hour 30 85. Refer to problem no. 82, what is the required cycle time of the process to accommodate 180 applications per hour? a. 15 c. 40

b. 20 d. 60

Answer: b. 20 Max. no. of applications per hour = 180 application per hour CT = 3,600 = 20 seconds 180 15

A

15 C

15

20

15

B

E

F

D

20

86. Refer to problem no. 82, compute for the costs per application per hour involved in the current process. a. 30.60 c. 23.40 Answer: d. 38.25

109 | P a g e

b. 18.90 d. 38.25


Job

2014

No. of Worker & Labor Cost Current

A B C D E F

1 x 270 = 270.00 1 x 270 = 270.00 1 x 270 = 270.00 1 x 270 = 270.00 1 x 360 = 360.00 1 x 405 = 405.00 ------------1845.00 camera +450.00 ------------2295/ 60 applications P38.25 per application

87. Refer to problem no. 84, f or the costs per application per hour involved in the alternative process. a. 30.60 c. 23.62

b. 18.90 d. 38.25

Answer: c. 23.62 Job

No. of Worker & Labor Cost Alternative

A B C D E F

camera

1 x 270 = 270.00 1 x 270 = 270.00 2 x 270 = 540.00 2 x 270 = 540.00 1 x 360 = 360.00 1 x 405 = 405.00 ------------2385.00 +450.00 ------------2835/ 120 applications P23.62 per application

88. Given: From/To

A

B

C

15

50

E

A B

20

75

C

50

120

D E F

110 | P a g e

D

50 110

100 100

F 125 120


2014

Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building? a. A

D

B

C

E

F

b. C

F

B

E

A

D

c. B

E

A

F

C

D

d. D

C

B

E

A

F

Answer: c.

B

35

125

235

A 220

100

E

C 220

Zero non-adjacent loads

111 | P a g e

F

D


2014

Layout:

B

A

F

C

E

D

89. Given: Number of loads per week Department

1

1 2

2

3

50

100 30

3

4

5

20 50

10

20

4

6

100 50

5 6 Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building? a. 1

2

6

4

3

5

5

2

1

b.

4

3

6

2

6

5

3

4

1

c.

112 | P a g e


2014

d. 6

3

4

1

5

2

Answer: b.

10

5

50

50

50

2

100

30

4

1

3

20 6

100

20

Zero non-adjacent loads Layout: 5

2

4

1

3

6

90. Given: Number of loads per week Department

1

1. Administration 2. Social services 3. Institutions 4. Accounting

2

3

4

5

6

3

6

5

6

10

8

1

1

3

9 2

5. Education

1

6. Internal audit Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the l ayout of your building? a. 4

113 | P a g e

6

1

5

2

3


2014

b. 3

2

6

4

5

1

c. 1

5

4

3

6

2

6

3

2

5

1

4

d.

Answer: d.

1

Diagram:

6

8

3

Non-adjacent loads 5-2 1 5-4 2 Total = 3

2

9 10

5

1 6 2

114 | P a g e

3

6

1

5

4


2014

Layout: 6

3

2

5

1

4

91. Given: Loads/day From/To A B A B

C

30 30

D

E

60

20 30

C

80

D

40

E Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the l ayout of your building? a. C

A

D

E

C

B

D

A

B

D

E

A

B

b.

E

c.

C

115 | P a g e


2014

d.

A

E

C

B

D

Answer: c. Diagram:

30

C

B 30

80

80

D 40

E

60

A

20

Zero non-adjacent loads Layout: B

D

C A

E

92. Matthew Design Company has been asked to design the layout for a newly constructed office building of one of its clients. The closeness matrix showing the daily trips between its six department offices is given below. Department 1

1

2

3

25

90

4

5 105

3 4

125

6

6 165

2

5

116 | P a g e

Trips between Departments

125

25 105


2014


1

5

6

4

2

2

5

3

b.

4

1

6

c. 5

3

1

4

6

2

d. 1

3

6

2

5

4

Answer: b. Diagram:

105

2 25

125

5

3

90

25

105 125

4 117 | P a g e

1

165

6


2014


5

4

3

1

6

93. Given: Flow between Departments (Number of Moves) 7 8 1 2 3 4 5 6 20 75 175 150 80

Departments 1. Shipping and receiving 2. Plastic molding stamping

90

100

120

125

350

3. Metal forming 4. Sewing department

25

25

5. Small toy assembly

180

187

6. Large toy assembly

374

103 7

7. Painting 8. Mechanism assembly

Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building? a.

118 | P a g e

5

1

2

6

4

3

7

8


b.

1

7

5

2

6

3

8

4

4

5

6

1

3

2

8

7

6

4

7

8

2

5

1

3

c.

d.

119 | P a g e

2014


Answer: d.

2014

25 4

6

Diagram:

125

374

25 100

103 7

7

120

8

175

187 2

180

2

350

90

75 5

3

1

80

150


4

7

8

2

5

1

3

94. Given: From/To

Stores

Stores

Turning

Milling

Press

Plate

Assembly

6

12

9

1

4

Turning

3

Warehouse

4

Milling

7

2

Press

3

1

1

4

3

Plate Assembly Warehouse

120 | P a g e

1 1

3

7


2014

Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the l ayout of your building?

a.

Press

W arehouse

W arehouse

Plate

Milling

Stores

Turning

b.

Turning

Stores

Milling

Press

W arehouse

Plate

Assembly

c.

Assembly

W arehouse

Turning

Plate

Press

Assembly

Stores

d.

121 | P a g e

Milling

Assembly

Plate

W arehouse

Turning

Stores

Press


2014

Answer: c. Diagram:

7

Assembly

W arehous e

1 2

4 8

Milling

Turning

3

Press

5

1

3

Plate

1

1

5

9

Non-adjacent load Assembly-Stores 5 Total = 5

Stores 6

Layout:

Assembly

W arehouse

Milling

Plate

Press

Turning

Stores

95. Based on the relationship chart below, what is it recommended layout?

122 | P a g e


a. 4

6

1

5

2

3

6

4

1

5

3

2

b.

c.

2

3

6

1

5 4

d.

6

3

2

5

1 4

Answer: c.

2

3

6

1

5 4

2

3

6

1

5

4 123 | P a g e

2014


96. Based on the relationship chart below, what is its recommended layout?

a. 5

b.

5

c.

6

d. 6

124 | P a g e

3

1

2

4

6

7

1

3

4

2

6

7

3

1

2

4

7

5

1

3

2

4

5

7

2014


2014

Answer: d.

6

6

1

3

2

4

5

7

1

3

2

4

5

7

97. Given: Legend: A I U

CV Values 10,000 100 0

Activity

Legend E O X

CV Values 1,000 10 -1,000

Area (sq. m)

1. W ood cutting

1,280

2. Receiving

560

A E I 3. Framing

1,280

U

I 4. Upholstery

U

1,120 E

5. Fabric storage

960

6. Fabric cutting

960

7. Sewing

640

E

U 8. Shipping

800

9. Offices

800

10. General Storage

480

U I

A A

X

U O

U

E

U U

X U

U

I U U

U

I

U I U

U

U

E O

Distance between departments: Adjacent = 1, Partial Adjacent = 0.5, Non-Adjacent = 0 Using CORELAP, what is Total Closeness Rating (TCR) Value of Department 1? a. 10,000 c. 12,000

b. 11,000 d. 14,000

Answer: c. 12,000 TCR – Department 1 = 10,000(1) + 1,000(1) + 100(0) + 10(0) + 0(6) + absolute - 1000 (1) = 12,000

125 | P a g e


2014

98. In reference to problem no. 97, what activity is the first to be placed on the grid? a. 7 c. 5

b. 2 d. 6

Answer: d. 6 TCR – Department 6 = 10,000(2) + 1,000(1) + 100(1) + 10(0) + 0(5) + absolute - 1000 (0) = 21,100 99. In reference to problem no. 98, what is your final layout? a.

2

10

5

6

1

3

7

8

4

9

10

1

7

3

5

6

8

9

2

10

1

4

8

9

2

3

5

6

b.

4

c.

7

126 | P a g e


d.

2

10

5

6

8

4

7

1

3

9

10

5

6

8

4

7

3

9

Answer: Answer: a.

1 2

DEPARTMENT

1

1

2

3

4

5

6

7

8

9

10

A

E

I

O

U

X

TCR

ORDER

A

E

U

X

U

U

U

U

U

1

1

0

0

6

1

12,000

5

I

U

E

E

X

I

U

I

1

2

3

0

2

1

13,300

3

I

U

U

U

U

U

U

0

1

2

0

6

0

1,200

8

E

I

I

I

U

U

0

1

4

0

4

0

1,400

6

2

A

3

E

I

4

U

U

I

5

X

E

U

E

A

E

U

U

U

1

3

0

0

4

1

14,000

2

6

U

E

U

I

A

A

A

U

U

U

2

1

1

0

5

0

21,100

1

7

U

X

U

I

E

A

U

U

O

O

1

1

1

2

3

1

12,120

4

8

U

I

U

I

U

U

U

O

O

E

0

1

2

1

5

0

1,210

7

9

U

U

U

U

U

U

O

O

O

0

0

0

3

6

0

300

10

10

U

I

U

U

U

U

O

E

0

1

1

2

5

0

1,120

9

127 | P a g e

O

2014


5000

10000

5000

10000

6

10000

5000

10000

5000

wp5

500

6000

10500

5000

1000

5

6

10000

500

6000

10500

5000

5-6 = A = 10,000

500

5-5-7 = E = 1,000 6-7 = A = 10,000 550

50

0

0

0

0

6

150

50

5

6

0

1150

7

150

100

4

7

0

50

100

50

50

100

50

0

1050

1000

5

500

4-5 = E = 1,000 4-6 = I = 100

8-5 = U = 0 8-6 = U =0

4-7 = I = 100

8-4 = I = 100 8-7 = U = 0 500

1000

0

0

0

5

6

0

0

0

0

0 0

1000

8

4

7

10

0

10

5

6

500

1000

505

10

5

0

8

4

7

0

0

50

100

50

0

8-10 = E = 1,000 5-10 = U = 0 6-10 = U = 0

3-10 = U =0 3-5 = U = 0

3-8 = U = 0 3-4 =I =100

4-10 =U = 0

3-6 = U = 0

3-7 = U = 0

7-10 = O = 10 0

0

50

500

1500

1500

500

5

6

5

150

10

5

6

500

4

7

10

5,150

8

4

7

-500

1

3

10

5

10050

1

3

9

-500

0

0

0

5000

10050

5100

50

0

10 0

10

0

8

0 0

5

9-10 = O =10

2-10 = I =100

9-5 = U = 0

2-8 = I = 100

9-6 = U = 0

2-1 = A = 10,000

9-8 = O = 10

2-3 = I = 100

9-4 = U = 0

2-9 = U = 0

9-7 = O = 10

2-7 = X = -1000 2-6 = E = 1,000 2-5 = E = 1,000

9-1 = U = 0 9-3 = U = 0 FINAL

2

128 | P a g e

10

5

6

8

4

7

1

3

9

2014


2014

100. Given:

A B C D E F G H I J K L

Machines

Parts-Machines Matrix Parts 1 2 3 4 5 x x x x x x x x x x x x x x x x

6 x

7

8

x x x x x x

x

x x

x

Using Digital Clustering Algorithm (DCA), prepare the final cell formation with additional machines, if needed. a.

5

6

1

4

X

X

X

X

2

8

7

A

X

X

X

H

X

X

X

B

X

X

J

X

L

X X

X

X

G

X

X

D

K

3

X

C

X

X

F

X

X

I

X

X

E

b.

X

5

6

1

4

X

X

X

X

A

X

X

X

H

X

X

X

B

X

X

J

X

X

D

L1 G K L2

2

8

X

X

X

X

7

3

X X

C

X

X

F

X

X

I

X

X

E

129 | P a g e

X


c.

5

6

1

4

X

X

X

X

7

3

2

8

A

X

X

X

H

X

X

X

B

X

X

J

X

C

X X

X

F

X

X

I

X

X X

X

L

X

X

G

X

X

D

E

X

K

d.

X

5

6

1

4

X

X

X

X

7

3

A

X

X

X

H

X

X

X

B

X

X

J

X

X

C

X

X

F

X

X

I

X

X

D

E1

2

8

X x

x

L

X

X

G

X

X

E2

K

X

Answer: b.

5

6

1

4

X

X

X

X

A

X

X

X

H

X

X

X

B

X

X

J

X

X

D

L1 G K

2

8

X

X

X

X

7

3

X X

L2 C

X

X

F

X

X

I

X

X

E

130 | P a g e

X

2014


Solutions: 

Present machine layout and parts m ovement PRESENT LAYOUT PARTS

MACHINES

1

OUTPUT/ASSEMBLY

A B

2 C 3

5

D 4

E F

5

G 6

6

H

7

3

I

1

8

J

4

K 7

L



2 8

Sum of Xs per column and row in order

5

1

4

X

X

X

A

X

X

X

H

X

X

X

X

X

X

X

D

L

2

3

X

X

6

8

X

7

X

B C

X

F G

X

X X

I

X X

X

X

J E K

131 | P a g e

X X

2014




Matrix with sorted columns 5

6

1

4

X

X

X

X

A

X

X

X

H

X

X

X

X

X

D

L B

2

8

7

X

X

X

C

X

X

F

X

X

X

X

G

X

X

I J

X

X

E

X

K



X

Matrix with sorted rows 5

6

1

4

X

X

X

X

2

8

7

A

X

X

X

H

X

L

X

X

X

G

X

X

D

X

X

B

X

X

J

X

X

K

3

X

C

X

X

F

X

X

I

X

X

E



3

X

Final cell formation with additional machines, if needed 5

6

1

4

X

X

X

X

A

X

X

X

H

X

X

X

B

X

X

J

X

X

D

L1 G K L2

8

X

X

X

X

7

3

X X

C

X

X

F

X

X

I

X

X

E

132 | P a g e

2

X

2014




Proposed cellular layout PROPOSED LAYOUT PARTS

MACHINES

OUTPUT/ASSEMBLY

5

D

5

6

A

1

H

6

B 4 J 2

1 4

L G

2

8

K

8

7

L2

3

C F

133 | P a g e

I

7

E

3

2014

2014 - Solved Problems in Facility Planning(1)

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