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Process Layout Design - Practice Questions

This document contains three practice questions about determining workstation and area requirements for manufacturing processes. The first question involves calculating the number of machines needed and total plant area to produce three products based on demand forecasts, production rates, and downtime. The second question similarly calculates machine needs and area based on annual demand and cycle times for three new parts. The third question calculates the number of machines needed to meet an annual production requirement of 40,000 units, and estimates the savings from operating a second shift to reduce machine needs.

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syed ali
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141 views

Process Layout Design - Practice Questions

This document contains three practice questions about determining workstation and area requirements for manufacturing processes. The first question involves calculating the number of machines needed and total plant area to produce three products based on demand forecasts, production rates, and downtime. The second question similarly calculates machine needs and area based on annual demand and cycle times for three new parts. The third question calculates the number of machines needed to meet an annual production requirement of 40,000 units, and estimates the savings from operating a second shift to reduce machine needs.

Uploaded by

syed ali
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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WS & ME (Batch 2017-21) 5th Semester (2020)

Process Layout Design – Practice


Questions
Activity Relationship Charts

1. A factory has five production departments: M (milling), D (drilling), T (turning), G


(grinding), and F (finishing). Products are routed for processing through these
departments in the quantities and sequences indicated in the table below, (a) Based on
these data, construct the From-To chart, (b) Develop the activity relationship chart for
these five departments, given that the From-To chart is the only basis for it.

Product Quantities per Day Sequence


1 25 M-D-G
2 5 T-G-F
3 10 T-F
D-M-D-G-
4 50
F
5 25 M-T-F
6 15 M-G

2. A college office building has five departments: A (accounting office), B (bursar’s


office), C (credit department), D (data processing department), and E (educational
support services). Paper forms are routed for processing through these departments in
the quantities and sequences indicated in the table below, (a) Based on these data,
construct the From- To chart, (b) Develop the activity relationship chart for these five
departments, given that the From-To chart is the only basis for it.

Product Quantities per Day Sequence


1 20 A-B-D
2 13 B-E-A
3 10 E-C
4 30 D-A-B-D
5 25 A-C-E-B
6 18 C-B-E-D-A

Workstation and Area Requirements

1. A certain type of machine will be used to produce three products: A, B, and C. Sales
forecasts for these products are 52,000, 65,000, and 70,000 units/year, respectively.
Production rates for the three products are, respectively, 12, 15, and 10 pc/hr; and
scrap rates are, respectively, 5%, 7%, and 9%. The plant will operate 50 weeks/year,
10 shifts/week, and 8 hr/shift. It is anticipated that production machines of this type

IQTM, University of the Punjab, Lahore. Page 1 of 2


WS & ME (Batch 2017-21) 5th Semester (2020)

will be down for repairs on average 10% of the time, (a) How many machines will be
required to meet demand? (b) If each machine requires a floor area of 30 m2, and
there is a 25% aisle allowance that must be added to the total machine space, what is
the total plant area that must be planned for these three new products?

2. Future production requirements in a machine shop call for several automatic bar
machines to be acquired to produce three new parts (A, B, and C) that have been
added to the product line. Annual demand and machining cycle times for the three
parts are given in the table below. The machine shop operates one 8-hour shift for 250
days per year. The machines are expected to be 95% reliable, and the scrap rate is 3%.
(a) How many automatic bar machines will be required to meet the specified annual
demand for the three new parts? (b) If each bar machine requires a floor area of 175
ft2, and there is a 30% aisle allowance that must be added to the total machine space,
what is the total machine shop area that must be added for the three parts?

Part Annual Demand Machining Cycle Time (min)


A 25,000 5.0
B 40,000 7.0
C 50,000 10.0

3. A factory has just signed a contract with one if its best customers to produce 40,000
units of a certain part annually. The part will be made on a processing machine
designed specifically for the part. The machine costs $200,000, and its reliability
(availability) is estimated at 95%.The standard time for each unit is 16.5 min. The
plant normally operates one shift (40 hours/week, 50 weeks/year). Assume scrap rate
is 2% and worker efficiency is 100%. (a) How many machines will be needed to
meet production requirements? (b) If the plant were to operate a second shift (40
hours/week, 50 weeks/year) just for production of this part, and direct labor cost for
the operation is $10/hour, how much money would the company save by reducing the
number of machines required?

IQTM, University of the Punjab, Lahore. Page 2 of 2

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