Practice Problems: Chapter 9, Layout Strategy
Problem 1:
As in most kitchens, the baking ovens in Lori’s Kitchen in New Orleans are located in one area
near the cooking burners. The refrigerators are located next to each other as are the dishwashing
facilities. A work area of tabletops is set aside for cutting, mixing, dough rolling, and assembling of
final servings, although different table areas may be reserved for each of these functions.
Given the following Interdepartmental Activity Matrix, develop an appropriate layout for Lori’s
Kitchen.
Interdepartmental Activity Matrix
Cooking burners (A)
Cooking
Burners (A)
Refrigerators (B)
Dishwashing (C)
Work Area (D)
-
7
193
12
-
4
82
-
222
Refrigerator (B)
Dishwashing (C)
Work Area (D)
-
The present layout is:
A
B
C
with a distance of 10 feet between adjacent areas.
1
D
Computing the Load * Distance measure:
Load * Distance
A to B
7 * 10
A to C
193*20
A to D
12*30
B to C
4*10
B to D
82*20
C to D
222*10
Total
70
3860
360
40
1640
2220
8190
Develop a preferred layout. What is the sum of the loads * distance of your new layout?
2
Problem 2:
A firm must produce 40 units/day during an 8-hour workday. Tasks, times, and predecessor
activities are given below.
Task
Time (Minutes)
Predecessor(s)
A
2
-
B
2
A
C
8
-
D
6
C
E
3
B
F
10
D, E
G
4
F
H
3
G
Total
38 minutes
Determine the cycle time and the appropriate number of workstations to produce the 40 units per
day.
3
ANSWERS
Problem 1:
From the Activity Matrix, C and D should be next to each other and A should be next to C. The
other relationships are minor by comparison. One possible solution is:
B
A
C
D
with a distance of 10 feet between adjacent areas.
Computing the Load * Distance measure:
Load * Distance
A to B
7 * 10
70
A to C
193*10
1930
A to D
12*20
240
B to C
4*20
80
B to D
82*30
2460
C to D
222*10
2220
Total
7000
Further improvement is possible. Try analyzing the following layouts.
A
C
B
D
A
C
D
B
4
Problem 2:
Cycle time 
Production time available 8 hrs *60 minutes/hr 480


 12 minutes/cycle
Units required
40 units
40
Minimum number of workstations 

t
i
Cycle time

Work time required
Cycle time
38 minutes
 3.17 station
12 minutes/cycle
3.17 workstations must be rounded up to 4 as 3 workstations would not be able to produce the
required output.
One layout – not necessarily optimal
5