04_ch09_Layout_problems

Layout-1 Chapter 9. Layout Strategies  Process-Oriented layouts  Product-Oriented layouts Problem 1. Process Layout: Walter Company wants arrange the six departments to minimize interdepartmental material handling costs. Flow and cost tables are given. 1 2 3 Original Layout 4 5 6 Flow/Load Table Assigned Room Flow/Load Table Assembly Painting Machine Shop Receiving Shipping Testing Room 1 Assembly 0 50 100 0 0 20 Room 2 Painting   0 30 50 10 0 Room 3 Machine Shop     0 20 0 100 Room 4 Receiving       0 50 0 Room 5 Shipping         0 0 Room 6 Testing           0 Distance/Cost table Assigned Dept Distance/ Cost table Room 1 Room 2 Room 3 Room 4 Room 5 Room 6 Assembly Room 1 0 1 2 1 1 2 Painting Room 2   0 1 1 1 1 Machine Shop Room 3     0 2 1 1 Receiving Room 4       0 1 2 Shipping Room 5         0 1 Testing Room 6           0                 Total Cost Assigned Dept Total Cost Room 1 Room 2 Room 3 Room 4 Room 5 Room 6 Assembly Room 1 0 50  200   0 0   40 Painting Room 2   0 30  50  10  0  Machine Shop Room 3     0 40   0 100  Receiving Room 4       0 50  0  Shipping Room 5         0 0  Testing Room 6           0 Total Cost  570

Layout-2 1 2 3 Alternate Layout 4 5 6 Flow/Load Table Assigne d Room Flow/Load Table  P A  M  R  S   T Room 1 P 0  50 30  50  10   0 Room 2 A   0 100  0  0   20 Room 3 M     0 20  0   100 Room 4 R       0  50 0  Room 5 S         0   Room 6 T           0 Distance/Cost table Assigne d Dept Distance/ Cost table Room 1 Room 2 Room 3 Room 4 Room 5 Room 6   Room 1 0 1 2 1 1 2   Room 2   0 1 1 1 1   Room 3     0 2 1 1   Room 4       0 1 2   Room 5         0 1   Room 6           0                 Total Cost Assigne d Dept Total Cost Room 1 Room 2 Room 3 Room 4 Room 5 Room 6   Room 1 0  50 60   50 10  0    Room 2   0 100  0   0 20    Room 3     0  40 0  100    Room 4       0 50   0   Room 5         0 0    Room 6           0 Total Cost  480 Change % = 15.79 

Layout-3 Problem 2. A Missouri job shop has four departments. 100s of workpieces moved between work areas. It costs $0.50 to move 1 workpiece 1 foot in the job shop. Marrs’ goal is to find a layout that has the lowest material handling cost. Load Matrix   M D F P M — 6 18 2 D — — 4 2 F — — — 18 P — — — — Plan A Distance Matrix Plan A Load-Distance Matrix   M D F P   M D F P M — 20 12 8 M —  120 216  16  D — — 6 10 D — — 24   20 F — — — 4 F — — — 72  P — — — — P — — — — Cost= 46 8 x 100 x $0.50 = 23400 Plan B Distance Matrix Plan B Load-Distance Matrix   M D F P   M D F P M — 20 8 12 M — 120  144  24  D — — 10 6 D — — 40  12  F — — — 4 F — — — 72  P — — — — P — — — — Cost= 41 2 x 100 x $0.50 = 20600  Plan C Distance Matrix Plan C Load-Distance Matrix   M D F P   M D F P M — 20 10 6 M — 120  180  12  D — — 8 12 D — — 32  24  F — — — 4 F — — — 72  P — — — — P — — — — Cost= 44 0 x 100 x $0.50 = 22000 

Layout-4 Problem 3. Michael Plumb’s job shop has four work areas, A, B, C, and D. Distances given in feet. Workpieces moved, in 100s of workpieces per week, between pairs of work areas. It costs Michael $1 to move 1 work piece 1 foot. What is the weekly total material handling cost of the layout? TOTAL COST= 265 x 1 x 100= $26,500 Load Matrix (To and From; 100s)   A B C D A — 3 4 4 B 5 — 3 2 C 3 — — 6 D — 6 — — Load Matrix   A B C D A —  8  7  4 B — — 3  8  C — — —  6 D — — — — Distance Matrix (ft)   A B C D A — 4 9 7 B — — 6 8 C — — — 10 D — — — — Load-Distance/Cost Matrix   A B C D A —  32  63 28  B — — 18  64  C — — — 60  D — — — —