Exam 11: Layout Strategies

Takt time is

__________ is that element of balancing a work cell that superficially resembles cycle time.

McDonald's "Made for You" kitchen system represents a __________ use of layout decisions.

The __________ is a non-numeric method for determining which departments are located near one another, and which departments are kept farther apart.

You have been asked to balance a flow shop assembly operation to achieve an output rate of 80 units per eight-hour day. Task times and precedence relationships are shown in the table below. Task Predecessor(s) Duration (minutes) A -- 1.4 B -- 0.8 C A, B 0.4 D -- 1.8 E -- 0.4 F C 2.1 G , 2.0 H , 1.2 a. Draw the precedence diagram. b. Determine the desired cycle time. c. Determine the theoretical minimum number of stations needed. d. Balance this line using most following tasks. e. What is the efficiency of the line obtained in part d?

An electronics manufacturer makes remote control devices for interactive-cable-TV systems. The following assembly tasks must be performed on each device. Task Description Predecessor(s) Time (min) A Place circuit into circuit frame -- 0.50 B Solder circuit connections to central circuit control A 0.70 C Place circuit assembly in device frame B 0.40 D Attach circuit assembly to device frame C 0.30 E Place and attach display to frame -- 0.30 F Place and attach keypad to frame -- 0.20 G Place and attach top body of device to frame E, F 0.35 H Place and attach battery holder to frame D 0.40 I Place and attach bottom body of device to G, H 0.60 frame Test device I 0.30 a. Draw the precedence diagram for this problem. b. What is the sum of the task times? c. What cycle time will allow the production of 200 units over a ten-hour day? d. What is the theoretical number of workstations needed? e. Balance this assembly line using the heuristic most following tasks and the heuristic longest operation time. f. How do these two solutions differ? Which do you prefer; why?

A firm operates a flow shop building kitchen cabinetry for recreational vehicles. The major activities of this process are listed below. Task Duration (hours) Predecessor 1 Predecessor 2 Predecessor 4 A 4 -- 6 -- 2 6 3 3 5 1 a. Draw the appropriate network for this project. b. What would the cycle time be if the goal is to produce 20 units per month (the plant operates 160 hours per month)? c. What is the theoretical minimum number of workstations needed? d. Balance with the most following tasks heuristic. What tasks are assigned to which stations? e. What is the efficiency of the line obtained in part d?

An insurance claims processing center has six work centers, any of which can be placed into any of six physical departmental locations. Call the centers 1, 2, 3, 4, 5, and 6, and the departments A, B, C, D, E, and F. The current set of assignments is A-3, B-1, C-6, D-2, E-4, and F-5. The (symmetric) matrix of departmental distances, in meters is -- 5 30 20 15 20 -- 40 15 10 10 -- 50 20 5 -- 10 35 -- 5 -- The matrix of work flow (estimated trips per day) is among centers A -- 15 20 0 30 0 20 -- 50 0 160 10 0 50 -- 30 0 30 30 60 20 -- 70 0 40 0 0 10 -- 60 0 0 30 20 50 -- The firm estimates that each trip costs approximately $4. a. What is the cost of the current assignment? b. Use trial-and-error to find one improved assignment. c. What is that assignment, and what is its cost?

The central problem in product-oriented layout planning is

Develop a solution for the following line balancing problem, allowing a cycle time of 5 minutes. a. Draw the precedence diagram for the set of tasks. b. Calculate the theoretical minimum number of workstations. c. Balance this line using the longest task time heuristic. d. What tasks are assigned to which stations? e. Does the solution have the minimum number of stations? Explain. f. How much idle time is there, summed over all workstations? g. What is the efficiency of this line? Work Task Task Time (seconds) Task Predecessor(s) 70 - 60 120 60 - 240 , 100 190 ,

An airport is trying to balance where to place three airlines. The distance between terminals and the number of trips that travelers make between airlines per day are listed. Find the assignment that minimizes the distance travelers must walk. Airline A B C Trips to A - 60 80 Trips to B 50 - 120 Trips to C 100 75 - Terminal 1 2 3 Distance to Terminal 1 - 4000 5000 Distance to Terminal 2 4000 - 6000 Distance to Terminal 3 5000 6000 -

Which of the following is true of random stocking?

A focused work center is well suited to the production of a large family of products requiring similar processing, even if their demands are not very stable.

Balancing low-cost storage with low-cost material handling is important in a(n)

__________ is the maximum time that the product is available at each workstation.

Heuristics are problem-solving procedures that mathematically optimize the solution.

Which of the following is not a retail layout practice?

Category management is the use of computer software to evaluate the profitability of merchandising plans.

If the schedule calls for the production of 120 units per day and 480 minutes of production time are available per day, the maximum cycle time would be 4 minutes.

A facility is trying to set up an assembly line, and has identified the various tasks, and their relationship to each other, as shown in the following table. They wish to produce 600 units per day, working two 8-hour shifts. Task Preceding Task Time to perform (sec.) A -- 20 B -- 30 C -- 25 D -- 10 E A 55 F D, B, C 30 G E 25 H F, G 40 a. Draw a network diagram of precedence relationships. b. Compute the required cycle time per unit in seconds. c. Compute the minimum number of workstations required to produce 600 units per day. d. Balance this line using longest processing time. e. What is the efficiency of the line obtained in part d?