University of Southern California
Department of Industrial and Systems Engineering
ISE 310L Production I; Facilities and Logistics
Spring 2000
Assignment 2
Dr. Ardavan Asef-Vaziri
Due date March, 7, 2000
1-Machine of a manufacturing cell are given below.
Machine
Operation
1
2
3
4
5
6
7
Turn O.D.
Bore I.D.
Face ends
Grind O.D.
Grind O.D.
Inspect
Drill
Production Rate
(Pieces/Hr)
9
15
10
12
12
5
9
Machine Dimensions
(m)
3.5 by 1.5
3.0 by 1.6
2.5 by 1.5
3.0 by 1.5
3.0 by 1.5
3.0 by 3.0
1.5 by 2.5
The FT chart is as follows
1
2
1
-
112
2
12
-
3
74
3
82
5
73
5
6
61
59
53
35
31
-
174
Storage
25
16
20
300
30
20
Warehouse
45
180
23
6
7
7
226
-
4
4
5
16
23
14
-
325
75
-
Machines 4 and 5 are similar, assignment of parts to two machines are arbitrary. The raw
material is delivered into the cell by belt conveyor, and is sent out of the cell by another
belt conveyor. Width of the conveyor is .4 m. Design 2 alternative layouts. Use
FactoryCad and FactoryFlow and prepare 2 alternative layouts for this problem.
In one layout use conveyor for material handling inside the cell.
In the other layout use robot for material handling inside the cell. Each robot has a reach
of 2 m and its base is 1 by 1.
2-Production routings of 12 parts are given below. Use Rank clustering algorithm to
design a Group Technology layout for this system. (Only identify the Part/Machine
groups).
Part
Machi
ne
A
B
C
D
E
F
G
H
I
1
2
3
4
5
6
1
1
8
1
1
1
1
1
1
9
10
1
1
1
1
1
1
1
1
7
1
1
1
1
1
1
1
1
12
1
1
1
1
11
Group Assignment
Use material in January lecture notes, pages 286-296 the book, pictorial comparison of
process layout and product layout explained in class on Feb, 22, and any other references
to prepare a complete lecture note to teach Process layout, Product layout, and Group
Technology ( Cellular) layout. Then solve the following problem to support your lecture.
Problem. The production routings and the machine requirement for 4 parts are given
below.
Machine
Weld
Grind
Saw
Lathe
Mill
Drill
Paint
A
-
-
0.5
0.5
0.4
0.2
-
B
-
0.4
-
-
-
0.3
0.5
C
-
-
0.4
-
0.5
0.2
-
D
0.3
0.5
-
0.4
-
0.2
0.4
Part
For example; part A requires 0.4 milling machine.
Production volume of all parts are equal, unit loads of all parts are equal.
All machines are 2 by 2 squares. There should be 1 unit space between each pair of
adjacent machines. The total fixed cost of each machine including occupied space is
5000$.
Material handling is rectilinear between centroids of machines. Cost of moving one unit
load of each part for one unit of distance is 1$.
a) Define a set of criteria, i.e. number of machines, shop floor space, material handling
cost to analyze your design.
b) Design a product layout, process layout, and group technology layout for the above
system. Use FactoryCad for drawing and FactoryFlow for material handling analysis.
c) Conduct a break-even analysis