ISyE 3104: Introduction to Supply Chain Modeling: Manufacturing and Warehousing
Instructor: Spyros Reveliotis
Spring 2002
Homework #4
Due Date: Monday, 3/18/02
Reading Assignment:

From your textbook: Sections 10.4 and 12.3.1: 12.13.1.1.

The material posted on the Library Reserves on

Systematic Layout Planning (2 items )and

Cellular Manufacturing (1 item)

Optional: the material on Computerized Layout Planning.

An additional issue in the design of a manufacturing or warehousing system is the selection of the material handling equipment to be used for the transport and storage/buffering of the (Work-In-
Process) material. Beyond its primary role as a transferring mechanism or a staging unit, this equipment quite often plays the additional role of "hardwiring" the adopted operational logic and policies, and therefore, its selection, design and deployment is an integral part of the overall facility design and it must be done with special care. As an example, in a warehouse, a conveyor system quite often provides an automated sortation mechanism, beyond its primary transfer function. Finally, an important concern is that the selected configuration can support indeed the production rates sought by the facility. This capability will depend on many issues, including the physical capacity of the selected units, the (maximum) speed for their motion, the ergonomics of the selected configuration, etc.
Some interesting readings on the material handling equipment employed in modern production and warehousing facilities can be found in

Tompkins et al. (c.f. reference 5 in the syllabus) : Chapter 6

The site of College-Industry council on material handling education: http://www.mhia.org/et/mhe_tax.htm
(We might come back to this issue when we discuss the design of warehousing systems)
Problem Set:
1.
Problem 12.8 from your textbook.
2.
The Multiple Products Company manufactures multiple products. Six departments are involved in the processing required for the products. A summary of the processing sequences required for the major 10 products and their monthly production volumes are as follows:
Product Processing Sequence Mo. Prod.
1 A B C D E F 800
2
3
A B C B E D C F
A B E F
1000
600
6
7
4
5
A B C E B C F
A C E F
A B C D E F
A B D EC B F
2000
1500
400
2000
8
9
A B C B D B E B F
A B C D F
10 A B D E F
2500
800
1000

The required departmental areas are also given below:
Dept.
Area (ft^2)
A
B
C
D
1000
1200
800
1500
E
F
2500
1500
The available facility is a rectangular with dimensions 120 ft x 75 ft.
(a) Develop a departmental layout for this facility using the SLP method presented in class.
(b) Compute the total distance traveled per month based on the design obtained in part (b). Assume rectilinear distance between departmental centroids and that moves between departments are made on the basis of production lots of 100 units per move. ( Remark: The rectilinear distance between two points (x1,y1) and (x2,y2) is defined by |x1-x2|+|y1-y2|, and it is motivated by the assumption that the traveling takes place on grid-like aisle system.)
3.
The accompanying table lists the sequence of machine types required for nine part types produced by a manufacturing facility:
Part type Machine sequence
1
2
3,5,2
3,5
5
6
3
4
7
4,6,1
1,4
6,4
1,6
2,5,3
8
9
5,3
6,1,4
(a) Set up a part-machine processing indicator matrix for the data in the table.
(b) Determine machine groups and part families using
(i)
(ii) the ROC algorithm; the SC approach.
Extra credit (5%)
Read from the relevant handout posted on the library reserves the material on the Row and Column
Masking (R&CM) clustering algorithm, and apply it on the data of Problem 3.