Sheet 2 FP

Zagazig University Course : Forecasting
Faculty of Engineering Code: IE 425 Sheet No. 2

Industrial Engineering Department Subject: Facility Planning
Year : 2014-2015, 1st term Dr. Yehya Mesalam
1- Develop a bill of materials, an assembly chart, and an operation process chart for a selected
product (Assume any product) with everything on it. Identify the components that are
purchased and the ones that are prepared internally.
2- State three differences between the assembly chart and the operation process chart.
3- A computer recycler sells computer enclosures to a computer remanufacturer. To meet

monthly expected demand, the remanufacturer needs 2,000 enclosures. The recycler utilizes a
four-step disassembly process with scrap rates given as follows: d^ = 0.08, d2 = 0.05, d3 =
0.05, and d4 = 0.03. How many computers must the recycler receive each month in order to
meet the remanufacturer’s demand?
4- Consider a simple three-step manufacturing process as illustrated in the given figure.
Assuming that demand is 1,000 units, what is the required input to meet demand? You’ll note
that the required input is the same if the scrap rates are reversed for processes 1 and 3-
Assume that the scrap cost is $5 at process 1, $10 at process 2, and $15 at process 3- The
defective rates are 3%, 5%, and 7%, respectively. Compute the total scrap cost for the given
system and the system where the scrap rates are reversed. Which system would be preferred?
5- Consider Problem 4 where, in this case, each process is capable of rework. Given the
information in the following table, what is the input required to satisfy a demand of 1,000
units?
Process Defect Rate Rework Rate
1 3% 60%
2 5% 75%
3 7% 80%
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Sheet No. 2 Facility Planning
Suppose that scrap costs are negligible, and rework costs are $2, $3, and $4, respectively.
Calculate the rework cost for producing the 1,000 units. What happens to the rework cost if
the scrap rates on processes 1 and 3 are reversed?
Does this result agree with that of Problem 4?
6- Part X requires machining on a milling machine (operations A and B are required). Find the
number of machines required to produce 3000 parts per week. Assume the company will be
operating five days per week, 18 hours per day. The following information is known:
Operation Standard Time Efficiency Reliability Defect Rate
A 3 min 95% 95% 2%
B 5 min 95% 90% 5%
Note: The milling machine requires tool changes and preventive maintenance after every lot
of 500 parts. These changes require 30 minutes.
7- Given the figure below, operation 4 represents a rework operation on parts that fail
inspection upon completion of operation 2.
How many units must the process start with in order to meet the required output of 5000
units?
8- Given the information in Problem 7 and the information in the table below, how many
machines are needed to perform each operation (round up to nearest integer)? Assume
operations 1, 2, and 3 run for 16 hours per day, five days per week. Machine 4 is available for
eight hours per day, five days per week.
Page 2 of 4
Operation Standard Time Efficiency Reliability

1 3 min 100% 95%
2 2 min 95% 90%
3 5 min 102% 90%
4 10 min 90% 95%
Assuming that machines 1—3 are part of a dedicated manufacturing cell, that operation 4 is
performed by a general-purpose machine that is used specifically for rework, and that
machines needed for operation 4 are located somewhere else in the facility. Recommend an
alternative strategy for performing operation 4 (rework), discussing specifically the issues
related to your strategy (use numerical results if applicable).
9- A part requires three processing steps on two machines in the sequence A-B-A. The demand
for this part is 10,000 units per year. The company operates six days per week, eight hours
per day. Given the following performance data, find the number of each machine needed to
meet the demand.
Operation Machine Standard Time Efficiency Reliability Defects
1 A 5 min 108% 98% 3%
2 B 3 min 95% 95% 5%
3 A 3 min 90% 95% 5%
10- Given the following, what are the machine duce parts X and Y? fractions for machines A,
B, and C to pro-
Machine A Machine B Machine C
Part X standard time 0.15 hr 0.25 hr 0.1 hr
Part Y standard time 0.10 hr 0.10 hr 0.15 hr
Part X defect estimate 5% 4% 3%
Part Y defect estimate 5% 4% 3%
Historical efficiency 85% 90% 95%
Reliability factor 95% 90% 85%
Equipment availability 1600 hr/yr 1600 hr/yr 1600 hr/yr
Part X routing is machine A, then B, and then C; 100,000 parts are to be produced per year.
Part Y routing is machine B, then A, and then C; 200,000 parts are to be produced per year.
Setup times for parts X and Y are 20 minutes and 40 minutes, respectively.
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11- During one 8 -hrs shift, 750 nondefective parts are desired from a fabrication operation.
The standard time for the operation is 15 minutes. Because the machine operators are
unskilled, the actual time it takes to perform the operation is 20 minutes, and, on average,
one-fifth of the parts that begin fabrication are scrapped. Assuming that each of the machines
used for this operation will not be available for one hour of each shift, determine the number
of machines required.
12- Develop a tree diagram to identify the specifics on developing an operator certification
program.
13- Form a team and apply the seven management and planning tools for planning the
redesign of any of the following:
a) a local bank
b) a hospital
c) a university cafeteria
d) a laundry facility
e) a passenger area from a local airport
f) a bookstore
g) a university office building
h) a movie theater
Page 4 of 4

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Zagazig University Course : Forecasting

Faculty of Engineering Code: IE 425 Sheet No. 2

3- A computer recycler sells computer enclosures to a computer remanufacturer. To meet

4- Consider a simple three-step manufacturing process as illustrated in the given figure.

Operation Standard Time Efficiency Reliability

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