04_ch09_Layout_problems
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Texas A&M University, Corpus Christi *
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Course
ACCT 2301.
Subject
Industrial Engineering
Date
Apr 3, 2024
Type
docx
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14
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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
—
—
—
—
Layout-5
Problem 4. Work areas
are in a row 10 feet in between adjacent areas.
Given the following Interdepartmental Activity Matrix, develop an appropriate layout for Lori’s Kitchen. TC= 8190
Original Layout
A(C)
B ®
C (D)
D (W)
Interdepartmental Activity Matrix
Cooking
Burners
(A)
Refrigerator
s (B)
Dishwashin
g (C)
Work
Area (D)
Cooking
burners (A)
-
7
193
12
Refrigerator
(B)
-
4
82
Dishwashin
g (C)
-
222
Work Area
(D)
-
Distance Matrix
A
B
C
D
A
-
10
20
30
B
-
10
20
C
-
10
D
-
Activity-Distance Matrix
Cooking
Burners
(A)
Refrigerator
s (B)
Dishwashin
g (C)
Work
Area (D)
Cooking
burners (A)
-
70
3860
360
Refrigerator
(B)
-
40
1640
Dishwashing
(C)
-
2220
Work Area
(D)
-
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