SOLVED PROBLEMS IN
FACILITY PLANNING & DESIGN
September 2012
Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
Facility Planning: determines how an activity’s tangible fixed assets best support achieving the activity’s
objectives.
Facility Location: is the placement of a facility with respect to customers, suppliers, and other facilities
with which it interfaces.
Structural Design: consists of the building and services (e.g., gas, water, power, heat, light, air,
sewage).
Layout Design: consists of all equipment, machinery, and furnishings within the structure.
Handling System Design: consists of the mechanism by which all interactions required by the layout
are satisfied (e.g., materials, personnel, information, and equipment handling
systems).
Scrap Estimate
Ok =
Ik - PkIk
Ok =
Ik (1 - Pk)
Ik =
Ok/ (1- Pk)
I1 =
On/ (1- P1) (1- P2)… (1- Pn)
Where:
Ok =
desired output of non-defective product from operation k
Ik =
production input to operation k
Pk =
% of scrap produced in operation k
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Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
Equipment Fraction
F=
_____Total Time Required to Perform the Operation_______
Net Available Time to Complete the Operation per Machine
F=
SQ/ EHR
Where:
F=
number of machines required per period
S=
standard time per unit produced
Q=
number of units to be produced period
E=
efficiency or actual performance expressed as percentage of standard time
R=
reliability of the machine expressed as percentage of ―up time‖
Factor Analysis Technique
WS =
WxS
Where:
WS =
weighted score for each factor for each facility plan or location
W=
appropriate weight to each factor (typically between 0 to 1) based on the relative importance of
each.
S=
assigned score to each facility plan or location (typically between 0 to 100) with respect to each
factor identified.
Compute the sum of the weighted scores for each facility plan or location and choose a facility
plan or location with the highest score.
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Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
Center-Of-Gravity Technique
n
X=
Xi W i
i=1
_________________
n
Wi
i=1
n
Y=
Yi W i
i=1
_________________
n
Wi
i=1
Where:
X, Y = coordinates of the new facility at the center of gravity.
Xi, Yi = coordinates of the existing facility i.
Wi =
annual weight shipped from facility i.
Load-Distance Technique
n
LD =
lidi
i=1
Where:
LD =
the load distance value
li =
the load expressed as a weight, number of trips, or units being shipped from the proposed site to
location i.
di =
the distance between the proposed site and location i.
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Solved Problems in Facility Planning & Design
FORMULAS IN FACILITY PLANNING & DESIGN
di =
(xi – x)2 + (yi – y)2
Where:
(x, y) = coordinates of the proposed site
(xi,yi) = coordinates of the existing facility
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=
sum of task times
D=
desired output rate
OT =
operating time per period
E=
__ t___
N x CT
Where:
E=
t=
efficiency of the assembly line
sum of task times
N=
minimum number of work stations
CT =
cycle time
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2012
Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
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
observed 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 for 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 longest 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
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Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
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
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 value 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.
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Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
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:
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o
The first department selected is placed in the middle.
o
The placement of a department is determined by evaluating all possible locations around
the current layout in counterclockwise order beginning at the ―western edge‖.
o
The new department is located based on the greatest WP value.
Solved Problems in Facility Planning & Design
2012
FORMULAS IN FACILITY PLANNING & DESIGN
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 further 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 Acronyms:
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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Solved Problems in Facility Planning & Design
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ANSWER SHEET 1
PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE
NAME: _____________________________________
DATE: ____________________
1. _______
21. _________
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61. _________
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64. _ ________
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68. _________
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89. _________
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70. _________
90. _________
11. _______
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91. _________
12. _______
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72. _________
92. _________
13. _______
33. _________
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73. _________
93. _________
14. _______
34. _________
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94. _________
15. _______
35. _________
55. _________
75. _________
95. _________
16. _______
36. _________
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96. _________
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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 = __________%
Solved Problems in Facility Planning & Design
2012
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 (FMS) 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 facilities 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 material 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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b. System Principle
d. Work Principle
Solved Problems in Facility Planning & Design
2012
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.
b. 100 – 150 sq. ft.
d. 250 – 400 sq. ft.
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. PLANET
c. ALDEP
b. CORELAP
d. BLOCPLAN
15. A __________ is the quantity in which material is normally moved.
a. Distance
c. Block
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b. Unit Load
d. Grid
Solved Problems in Facility Planning & Design
2012
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 ignored.
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
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
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
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b. Process
d. Group Technology
Solved Problems in Facility Planning & Design
2012
24. A layout 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
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
b. Facility Location
d. Handling System Design
27. Which of the following is not a type of crane?
a. Jib
c. Hoist
b. Gantry
d. Stacker
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
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b. Most favorable solution
d. Satisfactory solution
Solved Problems in Facility Planning & Design
2012
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. PLANET
c. ALDEP
b. CORELAP
d. BLOCPLAN
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
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b. Plant Layout
d. Block Diagram
Solved Problems in Facility Planning & Design
2012
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
b. Randomized Storage
d. Class-Based Dedicated Storage
43. The arrangement of desired machinery and equipment 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 the 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, 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
45. It tells us how much to produce and when to produce.
a. Product Design
c. Process Design
b. Schedule Design
d. Facility 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’s Plant Layout Procedure
b. Apple’s Plant Layout Procedure
d. Muther’s Systematic Layout Planning
47. A ____________ is interpreted to mean adjacent.
a. Open
c. Line
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b. Close
d. Circle
Solved Problems in Facility Planning & Design
2012
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. A type of layout used when all machines involved in performing a particular process are grouped
together and when there exist many low-volume, dissimilar products to be produced.
a. Fixed Position Layout
c. Group Layout
b. Product Layout
d. Process Layout
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 conveyors 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
b. Precedence Diagram
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
b. System Principle
d. Work 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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b. Product Layout
d. Process Layout
Solved Problems in Facility Planning & Design
2012
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
b. Facility Location
d. Handling 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 Method
b. Production-Center Method
d. Converting 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
b. Product Layout
d. Process 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
b. Randomized Storage
d. Class-Based 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
b. L-Shaped Flow
d. Circular Flow
63. It contains the information concerning the structure of the product.
a. Parts List
c. Assembly Chart
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b. Bill of Materials
d. Engineering Drawing
Solved Problems in Facility Planning & Design
2012
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
b. Parts Standard
d. Number of Parts
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 process 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
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Solved Problems in Facility Planning & Design
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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 more 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
b. Exploded Drawing
d. Photograph of the Product
75. It establishes the prerequisite assembly steps that must be completed before performing a given
assembly step.
a. Operation Process Chart
c. Assembly Chart
b. Precedence Diagram
d. Route Sheet
76. It refers to the overall design concepts or morphologies embedded within the facilities 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 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.
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b. 800 – 1600 sq. ft.
d. 2,400 – 3,900 sq. ft.
Solved Problems in Facility Planning & Design
2012
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
b. Container Space Utilization
d. Storage Space Efficiency
83. It is the ratio of usable cube divided by the storage cube.
a. Container Nesting Ratio
c. Trailer Space Utilization
b. Container Space Utilization
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
b. Container Space Utilization
d. Storage Space Efficiency
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
b. Production-Center Method
d. Converting 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
21 | P a g e
b. Carousels
d. Automatic Dispenser
Solved Problems in Facility Planning & Design
2012
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
b. Center of Gravity Technique
d. Relationship Diagram 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
b. Cost
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. CORELAP
c. CRAFT
b. DCA
d. PROMODEL
95. It is an adaptation of the familiar 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
22 | P a g e
b. Multiproduct Process Chart
d. From-To Chart
Solved Problems in Facility Planning & Design
2012
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
b. Facility Location
d. Handling System Design
97. It is the time required to complete an item.
a. Desired Cycle Time
c. Actual Cycle Time
b. Lead Time
d. Balanced 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 Flexibility
23 | P a g e
b. Material Flexibility
d. Flow Flexibility
Solved Problems in Facility Planning & Design
2012
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
b. Production-Center Method
d. Converting Method
Answer: d. Converting Method
2. It is the most complex and flexible FMS 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 facilities planning?
a. An effective production facility
c. An efficient production system
Answer: c. An efficient production system
24 | P a g e
b. An efficient operations management
d. An effective operations management
Solved Problems in Facility Planning & Design
2012
7. A principle of material 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
b. System Principle
d. Work Principle
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
b. Facility Location
d. Handling System 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
Answer: c. Planar
25 | P a g e
b. Close
d. Non-Planar
Solved Problems in Facility Planning & Design
2012
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.
a. PLANET
c. ALDEP
b. CORELAP
d. BLOCPLAN
Answer: a. 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
b. Precedence Diagram
d. Route Sheet
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 ignored.
d. Travel costs are indirectly proportional to the planar distance used.
Answer: d. Travel costs are indirectly proportional to the planar distance used.
26 | P a g e
Solved Problems in Facility Planning & Design
2012
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
b. Distance-Weighted Adjacency-Based Scoring
d. Distance-Based Scoring
Answer: 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
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 layout 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
27 | P a g e
b. Apple’s Plant Layout Procedure
d. Muther’s Systematic Layout Planning
Solved Problems in Facility Planning & Design
2012
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
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
b. Facility Location
d. Handling System 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
b. Product Layout
d. Process Layout
Answer: a. Fixed Position 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
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
Answer: a. Prototyping
28 | P a g e
b. Bill of Materials
d. Assembly drawing
Solved Problems in Facility Planning & Design
2012
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 favorable 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
b. Center of Gravity Technique
d. Relationship Diagram 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.
a. PLANET
c. ALDEP
b. CORELAP
d. BLOCPLAN
Answer: b. 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
Answer: d. Placing Rating
29 | P a g e
b. Shape Ratio
d. Placing Rating
Solved Problems in Facility Planning & Design
2012
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
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
b. Randomized Storage
d. Class-Based Dedicated Storage
Answer: 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 the finished product.
a. Line Balancing
c. Plant Layout
30 | P a g e
b. Block Diagram
d. Relationship Chart
Solved Problems in Facility Planning & Design
2012
Answer: c. Plant Layout
44. A tabular record for presenting quantitative data about the movements of 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: d. Travel Chart
45. It tells us how much to produce and when to produce.
a. Product Design
c. Process Design
b. Schedule Design
d. Facility Design
Answer: b. Schedule 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’s Plant Layout Procedure
b. Apple’s Plant Layout Procedure
d. Muther’s Systematic Layout Planning
Answer: a. Immer’s Basic Steps
47. A ____________ is interpreted to mean adjacent.
a. Open
c. Line
b. Close
d. Circle
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: c. 4
49. A type of layout used when all machines involved in performing a particular process are grouped
together and when there exist many low-volume, dissimilar products to be produced.
a. Fixed Position Layout
c. Group Layout
Answer: d. Process Layout
31 | P a g e
b. Product Layout
d. Process Layout
Solved Problems in Facility Planning & Design
2012
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
Answer: c. Calculation 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.
Answer: b. 800 – 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: a. Chute 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
b. Precedence Diagram
d. Route Sheet
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
b. System Principle
d. Work Principle
Answer: d. Work 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: c. Group Layout
32 | P a g e
b. Product Layout
d. Process Layout
Solved Problems in Facility Planning & Design
2012
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
Answer: a. Parts List
57. It consists of mechanism by which all interactions required by the layout are satisfied.
a. Facility Planning
c. Layout Design
b. Facility Location
d. Handling System Design
Answer: d. Handling 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 Method
b. Production-Center Method
d. Converting Method
Answer: a. Roughed-Out 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 Layout
c. Group Layout
b. Product Layout
d. Process Layout
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
b. Randomized Storage
d. Class-Based Dedicated Storage
Answer: a. Shared Storage
61. It identifies the significant material flows and their corresponding paths.
a. Factory Flow Analysis
c. Line Analysis
Answer: a. Factory Flow Analysis
33 | P a g e
b. Group Analysis
d. Tooling Analysis
Solved Problems in Facility Planning & Design
2012
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
b. L-Shaped Flow
d. Circular Flow
Answer: a. Straight Line 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
Answer: b. Bill of Materials
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
b. Multiproduct Process Chart
d. From-To Chart
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
34 | P a g e
b. Handling System Design
d. Facility Location
Solved Problems in Facility Planning & Design
2012
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
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 more 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
35 | P a g e
b. Exploded Drawing
d. Photograph of the Product
Solved Problems in Facility Planning & Design
2012
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
b. Precedence Diagram
d. Route Sheet
Answer: b. Precedence Diagram
76. It refers to the overall design concepts or morphologies embedded within the facilities 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.
b. 8 to 8.5 ft.
d. 10 to 11 ft.
Answer: c. 9 to 10 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 Weight 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.
Answer: b. 200 – 300 sq. ft.
36 | P a g e
b. 200 – 300 sq. ft.
d. 400 – 500 sq. ft.
Solved Problems in Facility Planning & Design
2012
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
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
b. Container Space Utilization
d. Storage Space Efficiency
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
b. Container Space Utilization
d. Storage Space Efficiency
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
b. Container Space Utilization
d. Storage Space Efficiency
Answer: c. Trailer Space Utilization
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
b. Production-Center Method
d. Converting 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
37 | P a g e
b. Carousels
d. Automatic Dispenser
Solved Problems in Facility Planning & Design
2012
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
b. Center of Gravity Technique
d. Relationship Diagram 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 material 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
b. Equipment Efficiency
d. Equipment Planning
Answer: c. Equipment Fraction
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
Answer: d. Throughput
38 | P a g e
b. Cost
d. Throughput
Solved Problems in Facility Planning & Design
2012
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. CORELAP
c. CRAFT
b. DCA
d. PROMODEL
Answer: c. CRAFT
95. It is an adaptation of the familiar 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
b. Multiproduct Process Chart
d. From-To Chart
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
b. Facility Location
d. Handling System Design
Answer: b. Facility Location
97. It is the time required to complete an item.
a. Desired Cycle Time
c. Actual Cycle Time
b. Lead Time
d. Balanced 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
b. Unit Load Carrier
d. Automated Guided Vehicle
Answer: a. Conveyor
99. It is a way to visualize the amount of movement that occurs between departments.
a. Relationship Diagramming
c. Line Balancing
Answer: b. Block Diagramming
39 | P a g e
b. Block Diagramming
d. Digital Clustering Algorithm
Solved Problems in Facility Planning & Design
2012
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 Flexibility
Answer: c. Machine Flexibility
40 | P a g e
b. Material Flexibility
d. Flow Flexibility
Solved Problems in Facility Planning & Design
2012
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%
41 | P a g e
/100 X 100 = __________%
Solved Problems in Facility Planning & Design
2012
PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE
1. Belinda Fashion Wear is 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 factors?
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, and LCD panels and sells them around the world. It wants to construct a new 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
42 | P a g e
b. Hongkong, 82
d. Shanghai, 79
Solved Problems in Facility Planning & Design
2012
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 factors and ratings.
a. South
c. West B
b. West A
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 and 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
0.03
0.02
0.02
Sta. Rosa
80
75
90
60
80
75
70
60
90
40
65
90
90
60
Lipa
90
85
90
50
90
65
80
70
95
50
60
80
95
90
Bataan
70
95
60
60
85
70
85
55
70
65
70
95
90
70
Recommend a site based on these location factors and ratings.
a. Sta. Rosa
c. Bataan
43 | P a g e
b. Lipa
c. Subic
Subic
75
90
70
70
95
80
75
60
80
55
80
80
90
80
Solved Problems in Facility Planning & Design
2012
5. 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)
6. 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)
7. The Inah Burger restaurant chain in the previous problem is 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
8. 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 follows:
Town
X
Y
Population (10,000s)
Rosario
30
60
6.5
Dasmarinas
50
40
4.2
Trece Martirez 10
70
5.9
Silang
40
30
3.5
Determine best location for the outlet mall using the center-of -gravity method.
a. (32, 56)
c. (30, 54)
44 | P a g e
b. (33, 55)
d. (31, 52)
Solved Problems in Facility Planning & Design
2012
9. 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 market 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)
c. (23, 22)
b. (21, 20)
d. (20, 19)
10. 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
X = 15
Y = 85
W = 160
Taguig
X =42
Y = 145
W = 90
Mandaluyong
X = 88
Y = 145
W = 105
Makati
X = 125
Y = 140
W = 35
a. (77, 104)
c. (79, 106)
Pasay
X = 135
Y = 125
W = 60
Quezon City
X = 180
Y = 18
W = 75
b. (80, 107)
d. (81, 105)
11. Refer to problem no. 10, 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
12. 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
45 | P a g e
Weights
20
5
15
10
Ratings
Candelaria
4
8
8
10
Lucena
7
8
9
6
Lukban
5
4
7
10
Solved Problems in Facility Planning & Design
2012
Which city should they choose?
a. Candelaria, 340
c. Lukban 325
b. Lucena, 375
d. Lukban, 385
13. Caloy Distribution Center in Quezon City is due to be replaced with a much larger, 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)
14. The following 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)
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 fan 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
46 | P a g e
b. Subic, P140,000.00
d. Laguna, P160,000.00
Solved Problems in Facility Planning & Design
2012
16. 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
17. Refer to problem no. 16, compute the lead time required for assembling one briefcase.
a. 30
c. 80
b. 48
d. 45
18. Refer to problem no. 16, calculate the theoretical minimum number of workstations.
a. 3
c. 4
b. 2
d. 1
19. Refer to problem no. 16, 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.
47 | P a g e
20
EF
Solved Problems in Facility Planning & Design
2012
d.
30
25
25
A
BC
DEF
20. Refer to problem no. 16, compute the line’s efficiency.
a. 89%
c. 81%
b. 83%
d. 93%
21. Refer to problem no. 16, suppose the demand for briefcases increases to 80 cases per week.
Calculate a new cycle time
a. 30
c. 50
b. 35
d. 45
22. Refer to problem no. 21, balance the line based on the longest task time.
a.
35
45
AD
BCEF
45
35
AB
CDEF
30
30
A
BCD
30
25
25
A
BC
DEF
b.
c.
20
EF
d.
48 | P a g e
Solved Problems in Facility Planning & Design
2012
23. Refer to problem no. 21, calculate the new efficiency of the manufacturing process.
a. 89%
c. 81%
b. 83%
d. 93%
24. Refer to problem no. 21, calculate the theoretical minimum number of workstations.
a. 3
c. 4
b. 2
d. 1
25. 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.
Work Element
A
B
C
D
E
F
Predecessor
A
B
A, E
C, D
Performance Time (min)
1
2
2
4
3
4
a. 3
c. 4
b. 16
d. 13
26. Refer to problem no. 25, compute the theoretical minimum number of workstations.
a. 5
c. 2
b. 3
d. 4
27. Refer to problem no. 25, balance the line using incremental utilization method.
a.
3
3.25
3.25
3.25
AB
CDEF
CDEF
CDEF
2.5
2.5
5.5
5.5
ABC
DEF
DEF
b.
ABC
49 | P a g e
Solved Problems in Facility Planning & Design
2012
c.
3
3.25
3.25
3.25
AB
CEDF
CEDF
CEDF
CEDF
3.0
3.0
3.25
3.25
3.25
AB
AB
CEDF
CEDF
CEDF
3.25
d.
28. Refer to problem no. 25, calculate the efficiency of the assembly line.
a. 95%
c. 80%
b. 90%
d. 83%
29. 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
A Receive order
B Shape dough
C Prepare toppings
D Assemble pizza
E Bake pizza
F Deliver pizza
Precedence
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
30. Refer to problem no. 29, compute the lead time for the process.
a. 4
c. 14
b. 3
d. 13
31. Refer to problem no. 29, Calculate the theoretical minimum number of workstations.
a. 2
c. 4
50 | P a g e
b. 3
d. 5
Solved Problems in Facility Planning & Design
2012
32. Refer to problem no. 29, balance 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.
33. Refer to problem no. 29, compute the efficiency of the line.
a. 88%
c. 89%
b. 91%
d. 93%
34. Refer to problem no. 29, suppose demand increases to 160 pizzas per night. What is the new cycle
time?
a. 4
c. 14
b. 3
d. 13
35. Refer to problem no. 34, balance the line based on the longest task time method.
a.
3
5
3
3
AB
CD
E
F
51 | P a g e
Solved Problems in Facility Planning & Design
2012
b.
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
c.
d.
36. Refer to problem no. 34, calculate the new theoretical minimum number of workstations.
a. 2
c. 4
b. 3
d. 5
37. Neren’s Eye Care, Inc., is a full-service optical supplier that sells eyeglasses, contact lenses, a
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
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
-
Time
(min)
1.0
A
B
B
C, D
1.0
0.4
0.4
2.0
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
52 | P a g e
b. 2.4
d. 4.8
Solved Problems in Facility Planning & Design
2012
38. Refer to problem no. 37, 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
39. Refer to problem no. 38, what is the efficiency of the line?
a. 80%
c. 100%
b. 91%
d. 95%
40. 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
Read case
Gather data
Search literature
Load in data
Run computer analysis
Write/type case
a
a
b
d
c, e
1
4
3
1
4
4
a. 3
c. 5
b. 4
d. 5
41. 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
a. 10
c. 61
53 | P a g e
4
J
H
9
7
K
G
I
5
2
b. 19.2
d. 2
3
Solved Problems in Facility Planning & Design
2012
42. Refer to problem no. 41, balance the line based on the most number of followers.
a.
19
19
11
12
ABC
DFG
EHI
JK
19
19
18
5
ACB
DGF
EHJ
IK
19
17
13
12
ABC
DEG
FHI
JK
19
16
14
12
ACB
DFE
GHI
JK
b.
c.
d.
43. 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
Time (min)
A
B
C
D
E
F
G
H
I
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, B
C, D
E, F
F, G
D
0.35
0.35
0.70
0.50
0.50
0.20
0.20
0.50
0.10
a. 1.5
c. 0.10
54 | P a g e
b. 0.70
d. 3.4
Solved Problems in Facility Planning & Design
2012
44. Refer to problem no. 43, 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
DABI
CEF
1.40
1.40
b.
0.70
GH
c.
ABC
DEFG
0.60
HI
d.
1.45
DEAI
1.45
BCFG
0.50
H
45. Refer to Problem No. 43, What is the maximum output per week?
a. 1,600
c. 1,750
b. 1,715
d. 1,656
46. Refer to problem no. 43, 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
55 | P a g e
Solved Problems in Facility Planning & Design
2012
b.
1.30
1.40
DABI
CEF
1.40
1.40
0.70
GH
c.
ABC
DEFG
0.60
HI
d.
1.45
DEAI
1.45
BCFG
0.50
H
47. Refer to Problem No. 46, what is the maximum output per week?
a. 1,600
c. 1,750
b. 1,715
d. 1,656
48. Refer to problem no. 43, 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
DABI
CEF
1.40
1.40
b.
0.70
GH
c.
ABC
56 | P a g e
DEFG
0.60
HI
Solved Problems in Facility Planning & Design
2012
d.
1.45
DEAI
1.45
BCFG
0.50
H
49. Refer to Problem No. 48, what is the maximum output per week?
a. 1,600
c. 1,750
b. 1,715
d. 1,656
50. Refer to problem no. 43, calculate the maximum number of frames that can be assembles each week.
a. 2,557
c. 3,567
b. 2,452
d. 3,429
51. Refer to problem no. 50, 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
52. Refer to problem no. 50, 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
53. 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
A
B
C
D
E
a. 5
c. 15
57 | P a g e
Precedence
A
B
A
C, D
Performance Time (min)
4
5
2
1
3
b. 6
d. 16
Solved Problems in Facility Planning & Design
2012
54. Refer to problem no. 53, determine how many claims can actually be processed on your line.
a. 60/ day
c. 80/ day
b. 70/ day
d. 90/ day
55. A firm must produce 40 units/day during an 8-hour workday. Tasks, times, 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
56. 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. Several steps were to be
performed in the process. After examining the license renewal process, 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. Each application was a separate
process in the sequence. Santos determined that his office should be prepared to accommodate the
maximum demand of processing 120 renewal applicants per hour. He observed that the work was
unevenly divided among the clerks, and that the clerk who was responsible for checking violations
tended to shortcut her task to keep up with the other clerks. Long lines built up during the maximum
demand periods.
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 job except photography.
58 | P a g e
Solved Problems in Facility Planning & Design
2012
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
57. Refer to problem no. 56, 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
58. In addition to problem no. 57, 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
59. Refer to problem no. 56, what is the required cycle time of the process to accommodate 180
applications per hour?
a. 15
c. 40
b. 20
d. 60
60. Refer to problem no. 56, 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
61. Refer to problem no. 58, for the costs per application per hour involved in the alternative process.
a. 30.60
c. 23.62
b. 18.90
d. 38.25
62. 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 0.90. Find the fractional
machine number.
a. 1.12
c. 0.91
59 | P a g e
b. 0.85
d. 1.21
Solved Problems in Facility Planning & Design
2012
63. 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
64. 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 is 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
65. Refer to problem no. 64, estimate the percentage of time the furnaces will be idled.
a. 20%
c. 33%
b. 25%
d. 67%
66. 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
67. Refer to problem no. 66, what average output per hour can be expected from each cubicle, taking its use
factor and efficiency into account?
a. 211
c. 19
b. 30
d. 200
68. Refer to problem no. 66, how many enlarger cubicles are required?
a. 14
c. 16
60 | P a g e
b. 10
d. 12
Solved Problems in Facility Planning & Design
2012
69. 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
70. Refer to problem no. 69, how many molding machines would be required?
a. 4
c. 6
b. 8
d. 12
71. 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
b. 7
d. 9
72. Refer to problem 71, how many machines you will acquire/ buy on Year 2?
a. 5
c. 2
b. 7
d. 9
73. Refer to problem no. 71, how many machines you will acquire/ buy on Year 3?
a. 5
c. 2
b. 7
d. 9
74. Refer to problem no. 71, how many machines you will acquire/ buy on Year 4?
a. 1
c. 2
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b. 10
d. 9
Solved Problems in Facility Planning & Design
2012
75. Refer to problem no. 71, how many machines you will acquire/ buy on Year 5?
a. 1
c. 3
b. 10
d. 13
76. 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
77. 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
78. 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 minutes 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
79. 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
62 | P a g e
B
390
C
360
D
400
actual output = 306/ day
Solved Problems in Facility Planning & Design
2012
What is the process capacity?
a. 306
c. 450
b. 360
d. 1,600
80. Refer to Problem no. 79, what is the process efficiency?
a. 19%
c. 68%
b. 22.5%
d. 85%
81. 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
82. Refer to problem no. 81, 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
83. 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
63 | P a g e
Solved Problems in Facility Planning & Design
2012
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
84. Refer to problem no. 83, 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
85. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000
stoves if the good quality of each stove is 88%?
a. 13,200
c. 125,000
b. 1,800
d. 17,045
86. 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 in 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
87. 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
64 | P a g e
b. 5,364
d. 3,218
Solved Problems in Facility Planning & Design
2012
88. Given:
From/To
A
B
C
D
E
F
A
B
15
C
50
20
50
D
E
75
120
50
110
100
100
F
125
120
100
Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
A
B
C
D
E
F
C
B
E
F
A
D
B
A
F
E
C
D
D
B
E
C
F
A
b.
c.
d.
65 | P a g e
Solved Problems in Facility Planning & Design
2012
89. Given:
Department
1
2
3
4
5
6
1
Number of loads per week
2
3
4
5
6
50
100
20
30
50
10
20
100
50
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
4
3
6
2
6
5
3
4
1
6
3
4
1
5
2
b.
c.
d.
66 | P a g e
Solved Problems in Facility Planning & Design
2012
90. Given:
1.
2.
3.
4.
5.
6.
Department
Administration
Social services
Institutions
Accounting
Education
Internal audit
1
Number of loads per week
2
3
4
5
3
6
5
6
8
1
1
3
9
2
6
10
1
Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
4
1
2
6
5
3
3
6
4
2
5
1
1
5
4
3
6
2
6
3
2
5
1
4
b.
c.
d.
67 | P a g e
Solved Problems in Facility Planning & Design
2012
91. Given:
Loads/day
From/To
A
B
A
30
B
C
D
E
C
30
D
60
E
20
30
80
40
Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout 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
68 | P a g e
Solved Problems in Facility Planning & Design
2012
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
2
3
4
5
6
25
90
165
105
125 125
25
105
1
1
2
3
4
5
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
4
1
6
5
1
4
3
6
2
1
6
2
3
5
4
b.
c.
d.
69 | P a g e
Solved Problems in Facility Planning & Design
2012
93. Given:
Flow between Departments (Number of Moves)
7
8
1
2
3
4
5
6
20
75
175 150
80
120
90
100
125
350
25
25
180 187
374 103
7
Departments
1. Shipping and receiving
2. Plastic molding stamping
3. Metal forming
4. Sewing department
5. Small toy assembly
6. Large toy assembly
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.
5
1
2
6
4
3
7
8
1
7
5
2
6
3
8
4
b.
70 | P a g e
Solved Problems in Facility Planning & Design
2012
c.
4
5
6
1
3
2
8
7
6
4
7
8
2
5
1
3
d.
94. Giv en:
From/To
Stores
Turning
Milling
Press
Plate
Assembly
Warehouse
Stores
Turning
6
1
Milling
12
3
Press
9
Plate
1
4
7
3
Assembly
4
3
2
1
4
1
Warehouse
1
3
7
Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
71 | P a g e
Press
Warehouse
Warehouse
Plate
Milling
Stores
Turning
Solved Problems in Facility Planning & Design
b.
Turning
Stores
Milling
Press
Warehouse
Plate
Assembly
c.
Assembly
Warehouse
Turning
Plate
Press
Assembly
Stores
d.
72 | P a g e
Milling
Assembly
Plate
Warehouse
Turning
Stores
Press
2012
Solved Problems in Facility Planning & Design
95. Based on the relationship chart below, what is it recommended layout?
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
73 | P a g e
2012
Solved Problems in Facility Planning & Design
96. Based on the relationship chart below, what is its recommended layout?
a.
5
b.
5
c.
6
d.
6
74 | 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
2012
Solved Problems in Facility Planning & Design
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. Wood cutting
1,280
2. Receiving
560
A
E
U
I
3. Framing
U
1,280
I
4. Upholstery
U
1,120
E
5. Fabric storage
960
6. Fabric cutting
960
7. Sewing
640
E
800
9. Offices
800
10. General Storage
480
U
U
O
O
U
E
U
I
A
A
8. Shipping
I
X
E
U
U
I
U
U
U
U
X
U
U
I
U
U
U
U
I
U
U
U
U
O
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
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
75 | P a g e
10
5
6
1
3
7
8
4
9
2012
Solved Problems in Facility Planning & Design
b.
4
10
1
7
3
5
6
8
9
2
10
1
4
8
9
2
3
5
6
10
5
6
8
4
7
1
3
9
c.
7
d.
2
76 | P a g e
2012
Solved Problems in Facility Planning & Design
2012
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.
D
A
H
B
J
L
G
K
C
F
I
E
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
7
X
X
X
X
X
3
X
X
X
X
X
X
X
X
b.
D
A
H
B
J
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
L1
2
8
X
X
G
K
X
7
3
X
X
L2
X
C
F
I
E
c.
D
A
H
B
J
C
F
I
E
L
G
K
77 | P a g e
X
X
X
X
X
X
X
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
7
3
X
X
X
X
X
2
8
X
X
X
X
X
X
X
X
X
Solved Problems in Facility Planning & Design
d.
D
A
H
B
J
C
F
I
E1
E2
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
7
3
X
X
X
X
X
2
8
X
X
L
G
K
78 | P a g e
x
x
X
X
X
X
X
2012
Solved Problems in Facility Planning & Design
2012
SOLVED PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE
1. Belinda Fashion Wear is 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 factors?
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
79 | 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
Solved Problems in Facility Planning & Design
2012
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
Recommend a best site based on these location factors 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
80 | 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
East
85
85
70
75
60
70
90
55
70
Solved Problems in Facility Planning & Design
2012
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 and 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
0.03
0.02
0.02
Sta. Rosa
80
75
90
60
80
75
70
60
90
40
65
90
90
60
Lipa
90
85
90
50
90
65
80
70
95
50
60
80
95
90
Bataan
70
95
60
60
85
70
85
55
70
65
70
95
90
70
Subic
75
90
70
70
95
80
75
60
80
55
80
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 and Education
Cost of Living
Taxes
Incentive Package
Government Regulation
Environmental Regulation
Transportation
Space for Expansion
Urban Proximity
Total
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
5. 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
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Bataan
X = 20
Y=8
W = 12,000
Nueva Ecija
X = 30
Y = 14
W = 9,000
Solved Problems in Facility Planning & Design
2012
What are the coordinates of the center of these 3 provinces?
a. (25, 22)
c. (24, 17)
b. (18, 22)
d. (21, 19)
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
6. 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
7. The Inah Burger restaurant chain in the previous problem is 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
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b. Site B, LD = 15,325
c. Site C, LD = 15,255
Solved Problems in Facility Planning & Design
Answer: b. Site B, LD = 15,325
Site A: d1=
(X1 – Xa)2 + (Y1 – Ya)2
=
(100 – 350)2 + (300 - 300)
d2 =
(X2 – Xa)2 + (Y2 – Ya)2
=
d3 =
=
d4 =
(210 – 350)2 + (180 – 360)2
(250 – 350)2 + (400 – 300)2
d5 =
(X5 – Xa)2 + (Y5 – Ya)2
=
(400 – 350)2 + (300 – 300)2
d2 =
=
d3 =
=
d4 =
(100 – 150)2 + (300 - 250)2
(210 – 150)2 + (180 – 250)2
(250 – 150)2 + (400 – 250)2
=
(400 – 150)2 + (200 – 250)2
d3 =
=
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=
158.11
=
111.8
=
70.71
=
92.20
=
180.28
=
180.28
=
254.95
=
150
=
126.49
=
100
(X4 – Xb)2 + (Y4 – Yb)2
(X5 – Xb)2 + (Y5 – Yb)2
=
141.42
(X3 – Xb)2 + (Y3 – Yb)2
d5 =
d2 =
=
(X2 – Xb)2 + (Y2 – Yb)2
(300 – 150)2 + (150 – 250)2
=
184.39
(X1 – Xa)2 + (Y1 – Yb)2
=
Site C: d1 =
=
(X4 – Xa)2 + (Y4 – Ya)2
(300 – 350)2 + (150 – 300)2
=
250
(X3 – Xa)2 + (Y3 – Ya)2
=
Site B: d1 =
=
(X1 – Xc)2 + (Y1 – Yc)2
(100 – 350)2 + (300 - 300)2
(X2 – Xc)2 + (Y2 – Yc)2
(210 – 250)2 + (180 – 366)2
(X3 – Xc)2 + (Y3 – Yc)2
(250 – 250)2 + (400 – 300)2
2012
Solved Problems in Facility Planning & Design
2012
(X4 – Xc)2 + (Y4 – Yc)2
d4 =
(300 – 250)2 + (150 – 300)2
=
=
158.11
=
180.28
(X5 – Xc)2 + (Y5 – Yc)2
d5 =
(400 – 250)2 + (200 – 300)2
=
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
8. 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 follows:
Town
Rosario
Dasmarinas
Trece Martirez
Silang
X
30
50
10
40
Y
60
40
70
30
Population (10,000s)
6.5
4.2
5.9
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
9. 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 market population in each are as follows:
Bauan
X = 12
Y = 20
W = 26,000
84 | 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
Solved Problems in Facility Planning & Design
2012
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
10. 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
X = 15
Y = 85
W = 160
Taguig
X =42
Y = 145
W = 90
Mandaluyong
X = 88
Y = 145
W = 105
a. (77, 104)
c. (79, 106)
Makati
X = 125
Y = 140
W = 35
Pasay
X = 135
Y = 125
W = 60
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
11. Refer to problem no. 10, 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
Answer: b. Site A with LD = 40,391
85 | P a g e
b. Site A with LD = 40,391
d. Site B with LD = 43,542
Solved Problems in Facility Planning & Design
For Site A:
d Pasig
= (15 – 88)2 + (85 – 80)2)
= 73.17
d Taguig
= (42 – 88)2 + (145 – 80)2
= 79.63
d Mandaluyong
= (88 – 88)2 + (145 – 80)2
= 65.00
d Makati
= (125 – 88)2 + (140 – 80)2
= 70.49
d Pasay
= (135 – 88)2 + (125 – 80)2
= 65.07
d Quezon City
= (180 – 88)2 + (18 – 80)2
= 110.94
For Site B:
d Pasig
= (15 – 13)2 + (85 – 127)2
= 42.05
d Taguig
= (42 – 13)2 + (145 – 127)2
= 34.13
d Mandaluyong
= (88 – 13)2 + (145 – 127)2
= 77.13
d Makati
= (125 – 13)2 + (140 – 127)2
= 112.75
d Pasay
= (135 – 13)2 + (125 – 127)2
= 122.00
d Quezon City
= (180 – 13)2 + (18 – 127)2
= 199.42
2012
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
12. 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
86 | P a g e
b. Lucena, 375
d. Lukban, 385
Solved Problems in Facility Planning & Design
2012
Answer: b. Lucena, 375
Factor
Nearness to
markets
Labor cost
Taxes
Nearness to
suppliers
Weights
Ratings
Candelaria
Lucena
Lukban
Weighted Ratings
Candelaria
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 Weighted ratings:
13. Caloy Distribution Center in Quezon City is due to be replaced with a much larger, 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:
Cx = (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
14. The following 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
87 | P a g e
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
Solved Problems in Facility Planning & Design
a. (7, 5)
c. (4, 8)
2012
b. (8, 4)
d. (5, 7)
Answer: d. (5, 7)
The new hub should be located close to:
Cx= (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
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 fan 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 location.
16. 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
88 | P a g e
b. 40
d. 48
Solved Problems in Facility Planning & Design
Answer: 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)
17. Refer to problem no. 16, 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
18. Refer to problem no. 16, 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
19. Refer to problem no. 16, balance the line based on the most number of followers.
a.
35
45
AD
BCEF
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2012
Solved Problems in Facility Planning & Design
b.
45
35
AB
CDEF
30
30
A
BCD
30
25
25
A
BC
DEF
c.
20
EF
d.
Answer: b
Task
A
B
C
D
E
F
45
35
AB
CDEF
Time
30
15
10
5
10
10
Station 1
A (48 – 30 = 18)
B (18 – 15 = 3)
ST1 = 45 mins
Number of Followers
4
3
2
2
1
0
Station 2
C (48 – 10 = 38)
D (38 – 5 = 33)
E (33 – 10 = 23)
F (23 – 10 = 13)
ST2 = 35 mins
20. Refer to problem no. 16, compute the line’s efficiency.
a. 89%
c. 81%
90 | P a g e
b. 83%
d. 93%
2012
Solved Problems in Facility Planning & Design
2012
Answer: b. 83%
lead time
Efficiency =
=
(30 + 15 + 10 + 5 + 10 + 10)
no. of workstations x cycle time
= 83.33%
2(48)
21. Refer to problem no. 16, suppose the demand for briefcases increases to 80 cases per week.
Calculate a new cycle time.
a. 30
c. 50
b. 35
d. 45
Answer: a. 30
Cycle time =
total working hours
=
(5 days x 8 hours/day x 60 minutes/hour)
desired units of output
(80 cases)
22. Refer to problem no. 21, balance the line based on the longest task time
a.
35
45
AD
BCEF
45
35
AB
CDEF
30
30
A
BCD
30
25
25
A
BC
DEF
b.
c.
20
EF
d.
91 | P a g e
= 30 minutes
Solved Problems in Facility Planning & Design
2012
Answer: c
30
30
A
BCD
Time
30
15
10
5
10
10
Rank
1
2
3
6
4
5
Task
A
B
C
D
E
F
Station 1
A (30 – 30 = 0)
20
EF
Station 2
B (30 – 15 = 15)
C (15 – 10 = 5)
D (5 – 5 = 0)
ST2 = 30 mins
ST1 = 30 mins
Station 3
E (30 – 10 = 20)
F (20 – 10 = 10)
ST3 = 20 mins
23. Refer to problem no. 21, 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)
no. of workstations x cycle time
3(30)
24. Refer to problem no. 21, calculate the theoretical minimum number of workstations.
a. 3
c. 4
b. 2
d. 1
Answer: a. 3
N=
lead time
cycle time
92 | P a g e
=
(30 + 15 + 10 + 5 + 10 + 10)
30
= 2.66 ≈ 3 workstations
= 88.89%
Solved Problems in Facility Planning & Design
2012
25. 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.
Work Element
A
B
C
D
E
F
Predecessor
A
B
A, E
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
total working hours
Cycle time=
=
4
(40 hours x 60 minutes/hour)
desired units of output
= 4 minutes
(600 party cakes)
26. Refer to problem no. 25, 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
27. Refer to problem no. 25, balance the line using incremental utilization method
a.
3
3.25
3.25
3.25
AB
CDEF
CDEF
CDEF
93 | P a g e
Solved Problems in Facility Planning & Design
b.
2.5
2.5
5.5
5.5
ABC
ABC
DEF
DEF
3
3.25
3.25
3.25
AB
CEDF
CEDF
CEDF
CEDF
3.0
3.0
3.25
3.25
3.25
AB
AB
CEDF
CEDF
CEDF
3
3.25
3.25
3.25
AB
CEDF
CEDF
CEDF
c.
3.25
d.
Answer: c
3.25
CEDF
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
Incremental Utilization
25%
75%
62.5%
50%
62.5%
75%
81%
# 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
28. Refer to problem no. 25, calculate the efficiency of the assembly line.
a. 95%
c. 80%
b. 90%
d. 83%
Answer: c. 80%
Efficiency =
lead time
no. of workstations x cycle time
94 | P a g e
=
(1 + 2 + 2 + 4 + 3 + 4)
5(4)
= 80%
2012
Solved Problems in Facility Planning & Design
2012
29. 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
A Receive order
B Shape dough
C Prepare toppings
D Assemble pizza
E Bake pizza
F Deliver pizza
Precedence
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
=
(8 hours x 60 minutes/hour)
desired units of output
= 4 minutes
(120 pizzas)
30. Refer to problem no. 29, 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
31. Refer to problem no. 29, Calculate the theoretical minimum number of workstations.
a. 2
c. 4
b. 3
d. 5
Answer: c. 4
N=
lead time
cycle time
95 | P a g e
=
(2 + 1 + 2 + 3 + 3 + 3)
4
= 3.5 ≈ 4 workstations
Solved Problems in Facility Planning & Design
32. Refer to problem no. 29, balance 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
4
4
3
3
AC
BD
E
F
b.
c.
d.
Answer: d
Task
A
B
C
D
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
96 | P a g e
Station 3
E (4 – 3 = 1)
Station 4
F (4 – 3 = 1)
ST3 = 3 mins
ST4 = 3 mins
2012
Solved Problems in Facility Planning & Design
2012
33. Refer to problem no. 29, compute the efficiency of the line.
a. 88%
c. 89%
b. 91%
d. 93%
Answer: a. 88%
lead time
Efficiency =
=
(2 + 1 + 2 + 3 + 3 + 3)
no. of workstations x cycle time
= 87.5%
4(4)
34. Refer to problem no. 29, 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
2
B
A
3
3
3
D
E
F
C
2
Cycle time =
total working hours
=
(8 hours x 60 minutes/hour)
desired units of output
= 3 minutes
(160 pizzas)
35. Refer to problem no. 34, balance the line based on the longest task time method.
a.
3
5
3
3
AB
CD
E
F
3
2
3
3
3
AB
C
D
E
F
b.
97 | P a g e
Solved Problems in Facility Planning & Design
2012
c.
4
1
3
3
3
AC
B
D
E
F
4
4
3
3
AC
BD
E
F
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
36. Refer to problem no. 34, calculate the new theoretical minimum number of workstations.
a. 2
c. 4
b. 3
d. 5
Answer: d. 5
N=
lead time
cycle time
98 | P a g e
=
(2 + 1 + 2 + 3 + 3 + 3)
3
= 4.6 ≈ 5 workstations
Solved Problems in Facility Planning & Design
2012
37. 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
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
-
Time
(min)
1.0
A
B
B
C, D
1.0
0.4
0.4
2.0
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
1
1
A
B
C
E
2
D
0.4
Cycle time =
total working hours
desired units of output
=
(8 hours x 60 minutes/hour)
= 4.8 minutes
(100 eyeglasses)
Lead time = (1 + 1 + 0.4 + 0.4 + 2) = 4.8 minutes
38. Refer to problem no. 37, 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
99 | P a g e
= 240 eyeglasses
Solved Problems in Facility Planning & Design
1
1.8
2
A
BCD
E
2012
With maximum time in a workstation of 2 minutes it can produce 240 eyeglasses with 3 workers
39. Refer to problem no. 38, what is the efficiency of the line?
a. 80%
c. 100%
b. 91%
d. 95%
Answer: a. 80%
lead time
Efficiency =
=
(1 + 1 + 0.4 + 0.4 + 2)
no. of workstations x cycle time
= 80%
3(2)
40. 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
Read case
Gather data
Search literature
Load in data
Run computer analysis
Write/type case
a
a
b
d
c, e
1
4
3
1
4
4
a. 3
c. 5
b. 4
d. 6
Answer: b. 4
1
4
1
4
B
D
E
A
Cycle time =
C
F
3
4
total working hours
desired units of output
100 | P a g e
=
(15 weeks x 5 days)
(15 cases)
= 5 days
Solved Problems in Facility Planning & Design
lead time
N=
=
(1 + 4 + 3 + 1 + 4 + 4)
cycle time
2012
= 3.4 ≈ 4 workstations or students
5
41. 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
4
J
H
9
7
K
G
I
5
2
a. 10
c. 61
3
b. 19.2
d. 2
Answer: b. 19.2
Cycle time =
total working hours
=
(40 hours x 60 minutes/hour)
desired units of output
= 19.2 minutes
(125 stamp pads)
42. Refer to problem no. 41, balance the line based on the most number of followers.
a.
19
19
11
12
ABC
DFG
EHI
JK
19
19
18
5
ACB
DGF
EHJ
IK
b.
101 | P a g e
Solved Problems in Facility Planning & Design
c.
19
17
13
12
ABC
DEG
FHI
JK
19
16
14
12
ACB
DFE
GHI
JK
19
19
18
5
ACB
DGF
EHJ
IK
d.
Answer: b.
Task
Time
Number of Followers
Rank
A
B
C
D
E
F
G
H
I
J
K
8
5
6
10
2
4
5
7
2
9
3
7
6
6
5
4
4
4
3
1
1
0
1
3
2
4
7
6
5
8
10
9
11
Station 1
A (19.2 – 8 = 11.2)
C (11.2 – 6 = 5.2)
B (5.2 – 5 = 0.2)
ST1 = 19.0
102 | P a g e
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
2012
Solved Problems in Facility Planning & Design
2012
43. 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
Time (min)
A
B
C
D
E
F
G
H
I
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, B
C, D
E, F
F, G
D
0.35
0.35
0.70
0.50
0.50
0.20
0.20
0.50
0.10
a. 1.5
c. 0.10
b. 0.70
d. 3.4
Answer: a. 1.5
.10
I
.35
.50
A
D
.20
C
F
H .50
.70
B
E
.35
.50
G
.20
Cycle time =
total working hours
desired units of output
=
(40 hours x 60 minutes/hour)
= 1.5 minutes
(1600 frames)
44. Refer to problem no. 43, balance the assembly line based on the computed cycle time using
incremental utilization method
a.
1.4
1.2
.80
ABC
DEG
FIH
103 | P a g e
Solved Problems in Facility Planning & Design
b.
1.30
1.40
DABI
CEF
1.40
1.40
ABC
DEFG
1.45
1.45
DEAI
BCFG
0.70
GH
c.
0.60
HI
d.
0.50
H
Answer: c
1.40
1.40
ABC
DEFG
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
Effective CT = 1.40
45. Refer to Problem No. 44, what is the maximum output per week?
a. 1,600
c. 1,750
104 | P a g e
b. 1,715
d. 1,656
Incremental Util
23%
47%
93%
63%
33%
67%
80%
93%
63%
33%
40%
2012
Solved Problems in Facility Planning & Design
2012
Answer: b. 1,715
Maximum Output per Week =
2,400 mins per week
= 1,715 units/ week
-----------------------------1.40
46. Refer to problem no. 43, 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
DABI
CEF
1.40
1.40
ABC
DEFG
1.45
1.45
DEAI
BCFG
b.
0.70
GH
c.
0.60
HI
d.
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
105 | P a g e
No. of Task Followers
4
4
4
3
2
2
1
0
0
Rank
2
3
1
4
5
6
7
8
9
Solved Problems in Facility Planning & Design
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
Station 2
C (1.50 – 0.70 = 0.80)
E (0.80 – 0.50 = 0.30)
F (0.30 – 0.20 = 0.10)
2012
Station 3
G (1.5 – 0.20 = 1.30)
H (1.3 – 0.50 = 0.80)
ST = 1.5 – 0.10 = 1.40 ST = 1.5 – 0.80 = 0.70
Effective CT = 1.40
1.30
1.40
DABI
CEF
0.70
GH
47. Refer to Problem No. 46, 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
= 1,715 units/ week
-----------------------------1.40
48. Refer to problem no. 43, 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
DABI
CEF
1.40
1.40
ABC
DEFG
b.
0.70
GH
c.
106 | P a g e
0.60
HI
Solved Problems in Facility Planning & Design
d.
1.45
1.45
DEAI
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
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
Effective CT = 1.45
1.45
1.45
DEAI
BCFG
0.50
H
49. Refer to Problem No. 48, what is the maximum output per week?
a. 1,600
c. 1,750
b. 1,715
d. 1,656
Answer: d. 1,656
Maximum Output per Week =
107 | P a g e
2,400 mins per week
= 1,656 units/ week
-----------------------------1.45
2012
Solved Problems in Facility Planning & Design
2012
50. Refer to problem no. 43, calculate the maximum 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
8 hours
x
week
x
60 minutes
day
x
hour
1 frame
= 3428.57 ≈ 3429
0.70min
51. Refer to problem no. 50, 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 minutes/hour)
desired units of output
= 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
52. Refer to problem no. 50, 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
x
1 week
5 day
x
1 day
8 hour
x
1 hour
P60.00
Total cost = P1.42833 x 5 workers = P7.14 / frame
108 | P a g e
= P1.42833 / worker
Solved Problems in Facility Planning & Design
2012
53. 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
A
B
C
D
E
Precedence
A
B
A
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 =
=
desired units of output
(8 hours x 60 minutes/hour)
= 6 minutes
(80 insurance claims)
54. Refer to problem no. 53, 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
109 | P a g e
x
60 minutes
hour
x
_1 claim
= 80 / day
6 minute
Solved Problems in Facility Planning & Design
2012
55. A firm must produce 40 units/day during an 8-hour workday. Tasks, times, 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
56. 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. Several steps were to be
performed in the process. After examining the license renewal process, 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. Each application was a separate
process in the sequence. Santos determined that his office should be prepared to accommodate the
maximum demand of processing 120 renewal applicants per hour. He observed that the work was
unevenly divided among the clerks, and that the clerk who was responsible for checking violations
tended to shortcut her task to keep up with the other clerks. Long lines built up during the maximum
demand periods.
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 job except photography.
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Solved Problems in Facility Planning & Design
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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
Answer: a. 60
Precedence Diagram
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
57. Refer to problem no. 56, 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
111 | P a g e
Solved Problems in Facility Planning & Design
2012
CT = 40 seconds
Max. no. of applications per hour = 3,600 = 90 applications per hour
40
58. In addition to problem no. 57, 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
Answer: c. 120
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
59. Refer to problem no. 56, 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
112 | P a g e
Solved Problems in Facility Planning & Design
2012
60. Refer to problem no. 56, 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
Answer: d. 38.25
Job
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
61. Refer to problem no. 58, for 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
62. 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
113 | P a g e
b. 0.85
d. 1.21
Solved Problems in Facility Planning & Design
2012
Answer: c. 0.91
F = 1600(0.0004)/ (8 – 0.2)(0.90) = 0.91
63. 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
64. 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 is 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
65. Refer to problem no. 64, estimate the percentage of time the furnaces 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
114 | P a g e
= 24 furnace hours
= 8 furnace hours
= 16 hours
= 67% idle time
Solved Problems in Facility Planning & Design
2012
66. 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
67. Refer to problem no. 66, what average output per hour can be expected from 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
68. Refer to problem no. 66, how many enlarger cubicles are required?
a. 14
c. 16
b. 10
d. 12
Answer: d. 12
Number of cubicles = 210.5 prints/ hr required/ 18.9 prints/ hr-cubicle = 11.4 or 12 cubicles
69. 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
115 | P a g e
= (unit capacity) (utilization) (efficiency)
= 60 mins/ hr/ 1.5 mins/ part = 40 parts/ hr
= (40 parts/ hr) (0.50) (0.90) = 18 parts/ hr
Solved Problems in Facility Planning & Design
70. Refer to problem no. 69, 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
71. Given:
Year
vi.
vii.
viii.
ix.
x.
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
b. 7
d. 9
Answer: a. 5
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
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2012
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72. Refer to problem 71, how many machines you will acquire/ buy on Year 2?
a. 5
c. 2
b. 7
d. 9
Answer: c. 2
F1 = 945.017 x 2 = 4.9 = 5 machines
382.5
F2 = 1,181.271 x 2 = 6.2 = 7 machines
382.5
Therefore, buy only 2 machines (7 – 5 = 2) in year 2
73. Refer to problem no. 71, how many machines you will acquire/ buy on Year 3?
a. 5
c. 2
b. 7
d. 9
Answer: c. 2
F2 = 1,181.271 x 2 = 6.2 = 7 machines
382.5
F3 = 1,632.302 x 2 = 8.5 = 9 machines
382.5
Therefore, buy only 2 machines (9 – 7 = 2) in year 3
74. Refer to problem no. 71, how many machines you will acquire/ buy on Year 4?
a. 1
c. 2
b. 10
d. 9
Answer: a. 1
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
75. Refer to problem no. 71, 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
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2012
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2012
76. 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
77. 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
Answer: a. 5
Number of stamping machines
= (30,000/ 0.95)(1 minute/ T-shirt)/ (200)(60)(0.60)(0.90)
= 31,578.95/ 6480 = 4.9 = 5 machines
78. 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 minutes 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
118 | P a g e
b. 52
d. 56
Solved Problems in Facility Planning & Design
2012
Answer: d. 56
Given:
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
= 55.92 = 56 machines
79. 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
80. Refer to Problem no. 79, 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%
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2012
81. 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
82. Refer to problem no. 81, 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: c. 486
I =
I =
300 / (0.87)(0.91)(0.94)(0.93)(0.93)(0.96)
485.5 = 486
120 | P a g e
b. 288
d. 486
Solved Problems in Facility Planning & Design
2012
83. 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
84. Refer to problem no. 83, 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: c. 223
I =
I =
250 / (0.96)(0.98)(0.95)
279.72 motors = 280
85. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000
stoves if the good quality of each stove is 88%?
a. 13,200
c. 125,000
Answer: d.
I =
I =
I =
O/(1 - P)
15,000/(1 - 0.12)
17,045.45 = 17,045
121 | P a g e
b. 1,800
d. 17,045
Solved Problems in Facility Planning & Design
2012
86. 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 in 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
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
87. 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
88. Given:
From/To
A
B
C
D
E
F
122 | P a g e
A
B
15
C
50
20
50
E
75
120
50
110
D
100
100
F
125
120
Solved Problems in Facility Planning & Design
2012
Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
A
B
C
D
E
F
C
B
E
F
A
D
B
A
F
E
C
D
D
B
E
C
F
A
b.
c.
d.
Answer: c.
B
235
35
125
A
220
100
E
C
220
Zero non-adjacent loads
123 | P a g e
F
D
Solved Problems in Facility Planning & Design
2012
Layout:
B
A
F
E
C
D
89. Given:
Department
1
2
3
4
5
6
1
Number of loads per week
2
3
4
5
6
50 100
20
30
50
10
20
100
50
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
4
3
6
b.
124 | P a g e
Solved Problems in Facility Planning & Design
c.
2
6
5
3
4
1
6
3
4
1
5
2
d.
Answer: b.
5
10
50
50
2
3
20
20
100
Zero non-adjacent loads
Layout:
125 | P a g e
1
100
30
4
50
5
2
1
4
3
6
6
2012
Solved Problems in Facility Planning & Design
2012
90. Given:
Department
1. Administration
2. Social services
3. Institutions
4. Accounting
5. Education
6. Internal audit
1
Number of loads per week
2
3
4
5
6
3
6
5
6
10
8
1
1
3
9
2
1
Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
4
1
2
6
5
3
3
6
4
2
5
1
1
5
4
3
6
2
6
3
2
5
1
4
b.
c.
d.
126 | P a g e
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2012
Answer: d.
1
Diagram:
6
8
3
9
10
1
5
3
3
6
1
1
4
5
6
Non-adjacent loads
5-2 1
5-4 2
Total = 3
2
2
Layout:
6
3
2
5
1
4
91. Given:
Loads/day
From/To
A
B
A
30
B
C
D
E
C
30
D
60
E
20
30
80
40
Design a layout on a 2x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
C
A
D
E
B
127 | P a g e
Solved Problems in Facility Planning & Design
b.
C
B
D
A
B
D
E
A
A
E
C
B
E
c.
C
d.
D
Answer: c.
Diagram:
C
30
80
B
D
30
80
E
40
20
Zero non-adjacent loads
128 | P a g e
60
A
2012
Solved Problems in Facility Planning & Design
2012
Layout:
B
D
E
A
C
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
2
3
4
5
6
25
90
165
105
125 125
25
105
1
1
2
3
4
5
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
4
1
6
b.
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Solved Problems in Facility Planning & Design
c.
5
1
4
3
6
2
1
6
2
3
5
4
d.
Answer: b.
Diagram:
105
2
25
5
125
90
25
105
4
1
125
165
Zero non-adjacent loads
Layout:
130 | P a g e
3
2
5
3
4
1
6
6
2012
Solved Problems in Facility Planning & Design
2012
93. Given:
Flow between Departments (Number of Moves)
7
8
1
2
3
4
5
6
20
75
175 150
80
120
90
100
125
350
25
25
180 187
374 103
7
Departments
1. Shipping and receiving
2. Plastic molding stamping
3. Metal forming
4. Sewing department
5. Small toy assembly
6. Large toy assembly
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.
5
1
2
6
4
3
7
8
1
7
5
2
6
3
8
4
b.
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Solved Problems in Facility Planning & Design
c.
4
5
6
1
3
2
8
7
6
4
7
8
2
5
1
3
d.
Answer: d.
25
6
Diagram:
4
25
125
374
7
7
120
8
350
90
75
5
80
1
3
150
Zero non-adjacent loads
132 | P a g e
2
175
187
2
180
100
103
2012
Solved Problems in Facility Planning & Design
2012
Layout:
6
4
7
8
2
5
1
3
94. Giv en:
From/To
Stores
Turning
Milling
Press
Plate
Assembly
Warehouse
Stores
Turning
6
1
Milling
12
3
Press
9
Plate
1
4
7
3
Assembly
4
3
2
1
4
1
Warehouse
1
3
7
Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
Press
Warehouse
Warehouse
Plate
Milling
Stores
Turning
b.
133 | P a g e
Turning
Stores
Milling
Press
Warehouse
Plate
Assembly
Solved Problems in Facility Planning & Design
2012
c.
Assembly
Warehouse
Turning
Plate
Press
Assembly
Stores
d.
Milling
Assembly
Plate
Warehouse
Turning
Stores
Press
Answer: c.
Diagram:
7
Assembly
1
2
3
Turning
134 | P a g e
3
4
8
Milling
Plate
Warehous
1
3
Press
5
1
1
6
Stores
9
5
Non-adjacent load
Assembly-Stores 5
Total = 5
Solved Problems in Facility Planning & Design
Layout:
Assembly
Warehouse
Milling
Plate
Press
Turning
Stores
95. Based on the relationship chart below, what is it recommended layout?
a.
4
6
1
5
2
3
6
4
1
5
3
2
2
3
6
1
5
b.
c.
4
135 | P a g e
2012
Solved Problems in Facility Planning & Design
d.
6
3
2
5
1
4
Answer:
c.
2
3
6
1
5
4
2
3
6
1
5
4
96. Based on the relationship chart below, what is its recommended layout?
136 | P a g e
2012
Solved Problems in Facility Planning & Design
a.
5
b.
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
c.
6
d.
6
Answer: d.
6
6
137 | P a g e
1
3
2
4
5
7
1
3
2
4
5
7
2012
Solved Problems in Facility Planning & Design
2012
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. Wood cutting
1,280
2. Receiving
560
A
E
I
3. Framing
U
U
1,280
I
4. Upholstery
U
1,120
E
5. Fabric storage
960
6. Fabric cutting
960
A
E
A
7. Sewing
8. Shipping
640
800
9. Offices
800
10. General Storage
480
I
U
O
U
O
X
U
E
E
U
I
U
U
X
U
U
I
U
U
U
U
U
I
U
U
U
I
U
U
U
U
O
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
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
138 | P a g e
Solved Problems in Facility Planning & Design
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
139 | P a g e
2012
Solved Problems in Facility Planning & Design
d.
2
10
5
6
8
4
7
1
3
9
10
5
6
8
4
7
1
3
9
Answer:
a.
2
DEPARTMENT
1
2
3
4
5
6
7
8
9
10
140 | P a g e
1
A
E
U
X
U
U
U
U
U
2
A
I
U
E
E
X
I
U
I
3
E
I
I
U
U
U
U
U
U
4
U
U
I
E
I
I
I
U
U
5
X
E
U
E
A
E
U
U
U
6
U
E
U
I
A
A
A
U
U
U
7
U
X
U
I
E
A
U
U
O
O
8
U
I
U
I
U
U
U
O
O
E
9 10
U U
U I
U U
U U
U U
U U
O O
O E
O
O
A
1
1
0
0
1
2
1
0
0
0
E
1
2
1
1
3
1
1
1
0
1
I
0
3
2
4
0
1
1
2
0
1
O
0
0
0
0
0
0
2
1
3
2
U
6
2
6
4
4
5
3
5
6
5
X
1
1
0
0
1
0
1
0
0
0
TCR
ORDER
12,000
5
13,300
3
1,200
8
1,400
6
14,000
2
21,100
1
12,120
4
1,210
7
300
10
1,120
9
2012
Solved Problems in Facility Planning & Design
5000
10000
5000
10000
5000
6
10000
10000
5000
wp5
500
6000
10500
5000
1000
5
6
500
6000
10500
10000
5000
5-6 = A = 10,000
5-5-7 = E = 1,000
6-7 = A = 10,000
500
1000
1050
550
50
0
0
0
5
150
50
500
1150
50
6
7
150
50
100
50
5
4
6
7
100
50
100
4-5 = E = 1,000
4-6 = I = 100
4-7 = I = 100
0
0
0
8
6
7
10
0
1000
505
10
5
0
0
1000
1000
500
0
8-10 = E = 1,000
5-10 = U = 0
6-10 = U = 0
4-10 =U = 0
7-10 = O = 10
0
0
0
0
0
0
0
0
10
8
5
4
6
7
0
50
100
50
0
0
3-10 = U =0
3-5 = U = 0
3-6 = U = 0
3-8 = U = 0
3-4 =I =100
3-7 = U = 0
10
5
0
0
50
500
1500
1500
500
10
8
1
5
4
3
6
7
5
150
10
5,150
6
7
9
0
0
10050
5000
5
4
3
-500
5
10
8
1
10050
5100
50
10
0
9-10 = O =10
9-5 = U = 0
9-6 = U = 0
9-8 = O = 10
9-4 = U = 0
9-7 = O = 10
9-1 = U = 0
9-3 = U = 0
2-10 = I =100
2-8 = I = 100
2-1 = A = 10,000
2-3 = I = 100
2-9 = U = 0
2-7 = X = -1000
2-6 = E = 1,000
2-5 = E = 1,000
FINAL
2
141 | P a g e
0
0
0
8-5 = U = 0
8-6 = U =0
8-4 = I = 100
8-7 = U = 0
5
4
500
0
10
8
1
5
4
3
6
7
9
500
-500
0
2012
Solved Problems in Facility Planning & Design
2012
100. Given:
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
A
B
C
D
E
F
G
H
I
J
K
L
Machines
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.
D
A
H
B
J
L
G
K
C
F
I
E
b.
D
A
H
B
J
L1
G
K
L2
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
7
3
X
X
X
X
X
X
X
X
X
X
X
X
X
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
X
X
X
7
3
X
X
X
C
F
I
E
142 | P a g e
X
X
X
X
X
X
X
Solved Problems in Facility Planning & Design
c.
5
6
1
4
D
A
H
B
J
C
F
I
E
L
G
K
X
X
X
X
X
X
X
X
X
X
X
X
X
X
5
6
1
4
D
A
H
B
J
C
F
I
X
X
X
X
X
X
X
X
X
X
X
X
X
X
d.
7
3
X
X
X
X
X
2
8
X
X
X
X
X
X
X
X
X
7
3
X
X
X
X
X
X
E1
E2
2
8
x
x
X
L
G
K
X
X
X
X
X
Answer:
b.
D
A
H
B
J
L1
G
K
L2
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
X
X
X
X
7
3
X
X
C
F
I
E
143 | P a g e
X
X
X
X
X
X
X
2012
Solved Problems in Facility Planning & Design
Solutions:
Present machine layout and parts movement
PRESENT LAYOUT
PARTS
MACHINES
OUTPUT/ASSEMBLY
A
1
B
2
C
5
3
D
E
4
F
5
G
6
6
H
3
7
I
8
1
J
4
K
7
L
2
8
Sum of Xs per column and row in order
5
D
A
H
L
B
C
F
G
I
J
E
K
144 | P a g e
2
3
X
X
6
1
4
X
8
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
7
X
X
X
X
X
X
2012
Solved Problems in Facility Planning & Design
Matrix with sorted columns
D
A
H
L
B
C
F
G
I
J
E
K
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
2
8
7
X
X
X
X
X
3
X
X
X
X
X
X
X
X
X
X
Matrix with sorted rows
D
A
H
B
J
L
G
K
C
F
I
E
5
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
7
X
X
X
X
X
3
X
X
X
X
X
X
X
X
Final cell formation with additional machines, if needed
D
A
H
B
J
L1
G
K
L2
6
1
4
X
X
X
X
X
X
X
X
X
X
X
X
X
2
8
X
X
X
7
3
X
X
X
C
F
I
E
145 | P a g e
5
X
X
X
X
X
X
X
X
2012
Solved Problems in Facility Planning & Design
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
146 | P a g e
I
7
E
3
2012
Solved Problems in Facility Planning & Design
2012
REFERENCES
[1]
Clark, J. E., ―Facility Planning, Principles, Technology, Guidelines‖. Pearson Prentice Hall, 2008
[2]
Francis, R.L., McGinnis, L.F., Jr., and White, J.A. ―Facility Layout and Location – An Analytical
Approach, Second Edition‖. Prentice Hall, Inc., 1992
[3]
Garcia-Diaz, A., and Smith, J.M. ―Facilities Planning and Design‖. Pearson Prentice Hall, 2008
[4]
James, R. W. and Alcorn, P.A. ―A Guide to Facilities Planning‖. Pearson Prentice Hall, 1991
[5]
Russel, R.S. and Taylor, B.W., III ―Operations Management, Third Edition‖, Prentice Hall, Inc.,
2000
[6]
Schonberger, R.J., and Knod, E.M., Jr., ―Operations Management – Customer-Focused
Principles, Sixth Edition‖. Times Mirror Education Group, 1997
[7]
Tompkins J. A. et al., ―Facilities Planning, Latest Edition‖. J. Wiley, 2003
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