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• Hasan Shahrier

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IENG4445 & IENG6908 – FACILITIES DESIGN ASSIGNMENT 01 – 17/01/2020 Full Name:

Banner Number: B00

INSTRUCTIONS • •

This assignment must be done individually. A scanned or soft copy of your solutions must be uploaded to Brightspace. Please make sure to have only ONE file uploaded. A printed copy should be dropped off in the IE Department drop-off box on the 2nd Floor of the Morroy Academic Building

DUE DATE: JANUARY 27TH – 5:00PM.

Problem 1 (40) – Sketch a typical layout for each of the following retail store types: a) b) c) d)

Department store Fast food outlet A bank’s customer banking centre (branch) A supermarket style grocery store.

Answer:

Problem 2 (10) – 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? Assume that the unit 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.

Answer:

Problem 3 (10) – Part X requires machining on a milling machine (operations A and B are required). Find the number of milling machines required to produce 3,000 parts per week. Assume the company will be operating five days per week, 8 hours per day. The following information is known:

IENG4445 & IENG6908 – FACILITIES DESIGN ASSIGNMENT 01 – 17/01/2020 Standard Time 3 min 5 min

Operation A B

Defect Rate 2% 5%

Efficiency Reliability 95% 95%

95% 90%

Note: The milling machine requires tool changes and preventive maintenance after every lot of 500 parts. These changes require 30 minutes. Think of setup as an activity that reduces equipment availability. Answer:

Problem 4 (10) – A part requires three processing steps on two machines in the sequence A-BA. The demand for this part is 10,000 units per week. 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

1 2 3

A B A

Standard Time 5 min 3 min 3 min

Efficiency Reliability 90% 95% 90%

95% 98% 95%

Defect Rate 3% 2% 1%

Answer:

Problem 5 (10) – Given the following, what are the machine fractions for machines A, B, and C to produce parts X and Y? Machine Part X standard time Part Y standard time Part X defect estimate Part Y defect estimate Historical efficiency Reliability factor Equipment availability not accounting for efficiency or reliability

A 0.15 hr 0.10 hr 5% 5% 85% 95%

B 0.25 hr 0.10 hr 4% 4% 90% 90%

C 0.10 hr 0.15 hr 3% 3% 95% 85%

8760 hrs/yr

8760 hrs/yr

8760 hrs/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. Think of setup as an activity that reduces equipment availability. For both X and Y, a setup occurs every 200 parts on each machine.

IENG4445 & IENG6908 – FACILITIES DESIGN ASSIGNMENT 01 – 17/01/2020 Problem 6 (20) - It takes 3 minutes to load and 2 minutes to unload a machine and both machine and operator are required. Inspection, packing, and travel between machines totals one minute. Machines run automatically for 20 minutes. Operators cost $18 per hour; the opportunity cost of the machine is $30 per hour. a) What is the maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle? Create a multiple activity chart using excel. (4) b) What assignment minimizes the cost per unit produced? (4) c) If four machines are assigned to an operator, what will be the cost per unit produced? (4) d) For what range of values for concurrent activity is the optimum assignment equal to four? (8)