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Process Selection and Facility Layout

The document summarizes two facility layout problems - a process layout problem for an aircraft engine maintenance facility and a product layout problem for a multi-step production process. For the process layout problem, it provides the current layout of 8 departments, material flow data between departments, and the objective to minimize total distance traveled of materials. For the product layout problem, it provides task times and precedence relationships for 10 tasks and asks to determine cycle time, number of workstations, balance the line across workstations, and calculate efficiency.

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Mai Samalca
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164 views2 pages

Process Selection and Facility Layout

The document summarizes two facility layout problems - a process layout problem for an aircraft engine maintenance facility and a product layout problem for a multi-step production process. For the process layout problem, it provides the current layout of 8 departments, material flow data between departments, and the objective to minimize total distance traveled of materials. For the product layout problem, it provides task times and precedence relationships for 10 tasks and asks to determine cycle time, number of workstations, balance the line across workstations, and calculate efficiency.

Uploaded by

Mai Samalca
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Management 2 Assignment (Facility Layout)

A. Problem for Process Layout

Aero Maintenance is a small aircraft engine maintenance facility located in Wichita, Kansas. Its new
administrator, Ann Daniel, decides to improve material flow of facility, using the process layout method.
The current layout of Aero Maintenance’s eight departments is shown in the figure below:

Current Aero Maintenance Layout


Area A Area B Area C Area D
Entrance Receiving Parts Metallurgy 10’
(1) (2) (3) (4)
Breakdown Assembly Inspection Test
10’
(5) (6) (7) (8)
Area E Area F Area G Area H
40’

The only physical restriction perceived by Daniel is the need to keep the entrance in its current location.
All other departments can be moved to a different work area (each 10 ft square) if layout analysis
indicates a move would be beneficial.

First, Daniel analyzes records to determine the number of material movements among departments in an
average month. These data are shown below. Here objective, Daniel decide is to layout the departments
so as to minimize total movement (distance traveled) of material in the facility. She writes her objective
as:
8 8

𝑀𝑖𝑛𝑖𝑚𝑖𝑧𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑚𝑜𝑣𝑒𝑚𝑒𝑛𝑡 = ∑ ∑ 𝑋𝑖𝑗 𝐶𝑖𝑗


𝑖=1 𝑗=1

Where Xij = number of material movements per month (loads or trips) moving from department i to j
Where Cij = distance in feet betwwen departments i and j (which in this case, is equivalent of cost per
load to move between departments.

(Note that this is a slight modification of the cost-objective equation we have discussed)

Daniel assumes that adjacent departments, (please refere to the “FROM-TO” matrix below) such as
entrance (now in work area A) and receiving (now in work area B), have a walking distance of 10 feet.
Diagonal departments are also considered adjacent and assigned a distance of 10 ft. Non-adjacent
departments, such as the entrance and parts (now in area C) or the entrance and inspection (area G) are 20
feet apart, and nonadjacent rooms, such as entrance and metallurgy area (area D) are 30 feet apart.

Material Movements

Departments Entrance Receiving Parts Mettalurgy Breakdown Assembly Inspection Test


(1) (2) (3) (4) (5) (6) ((7) (8)
Entrance
(1)
100 100 0 0 0 0 0
Receiving
(2)
0 50 20 0 0 0
Parts
(3)
30 30 0 0 0
Mettalurgy
(4)
20 0 0 20
Breakdown
(5)
20 0 10
(Assembly)
(6)
30 0
Inspection
(7)
0
Test
(8)
Required:
1. Given the above information, develop a schematic diagram or an interdepartmental flow showing
the current maintenance layout of Aero.
2. Compute for the distance consumed for material movements.
3. Redesign Aero maintenance’s layout to improve its material flow efficiency. (Show a revised
schematic diagram and a computation of total distance covered for material movements.)

B. Problem for Product Layout

Task Task Time Immediate Predecessor


(seconds)
A 45 -
B 11 A
C 9 B
D 50 -
E 26 D
F 11 E
G 12 C
H 10 C
I 9 F, G, H
J 10 I

1. Develop the precedence diagram


2. Suppose there are seven working hours on a given day with an expected output of 500 units:
a. Determine the cycle time
b. Calculate the theoretical minimum number of workstations
c. Balance the line by assigning tasks to workstations
d. Determine efficiency and idle time percentage of the line

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