Académique Documents
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a
1
p
r
1
d
Example 1
p1
p3
4
p4
p2
s1
2
(2)
s2
(1)
5
p5
6
p6
3
d
s3
p1
Example 1 Solution
p3
490,000 10,000
d
200 units / hr. (good units)
2,500
d
200
p5 p 6
p5
212.76
p3 p4
22163
. units / hr.
(1 s2 )
0.96
4
p4
p2
s1
2
(2)
s2
(1)
5
p5
2 p5
2 212.76
p1 p 2
p6
3
d
s3
Example 2
Consider a product that requires a single operation. After the operation is
performed, each unit is inspected. A unit passes inspection with probability
0.92, is scrapped with probability 0.05, or has to be reworked with probability
0.03. If the demand for this product is 82,000 units per year and the annual
operating time is 2,500 hours, determine the production rate at the processing
station.
82,000
d
32.80 units / hr. (good units)
2,500
a
1
p
r
1
d
d
32.80
Notation:
K = setup cost ($/order).
c = unit purchasing or production cost ($/unit).
h = unit holding cost ($/unit/time unit).
X(t) = inventory on hand at time t.
T = cycle time (time between consecutive orders).
TCC
T
h Q2
K cQ
2a
aK
hQ
TC
ac
Q
Q
2
a
X(t)
-a
d TC a K h
0
dQ
2
Q2
Solution:
2a K
h
Q*
T*
Q*
TC*
: EOQ Formula
2a K
h
TC
TC*
2K
ah
aK
hQ*
ac
2Ka h ac
Q*
2
hQ
aK
Q
ca
Q*
0 Q < M1
c0
M1 Q < M2
c1
.
Mn-1 Q < Mn
.
cn-1
Mn Q
cn
2Ka
.
h
TC 2 a K h c i a ,
aK hMj
TC( M j )
a c j.
Mj
2
Step 4: Select the amount corresponding to the minimum total cost per time unit:
TC* = min {TC, TC(Mi+1), TC(Mi+2), , TC(Mn)}.
Q*
T*
2a K
2 32 25
40 rolls
1
Q * 40
125
. weeks
a
32
2 35 25
40 rolls
1
TC(50)
40 (10, 49)
32 25 1 50
TC(100)
32 25 1 100
9 32 $346 / week
100
2
Q* = 50 rolls
where
Q = lot size,
x = number of good parts,
pQ(x) = P{X=x : lot size is Q}, x=0,1,,Q,
R(Q,x) = revenue for producing Q parts with exactly x good ones,
C(Q,x) = cost for producing Q parts with exactly x good ones,
P(Q,x) = R(Q,x) - C(Q,x) : profit for producing Q parts with x good ones,
E[] = expected value.
Example 5
A company receives an order for 10 machined parts. The unit sale price is $1,000. Only
one production can be made due to the long setup time required and short due date of the
order. If 8 or fewer parts are acceptable, the customer will cancel the order. If 9 or 10 parts
are acceptable, the customer will purchase all of them. If more than 10 parts are acceptable,
the customer will only buy 10. The remaining parts, good or bad, can be sold for $25 each.
The cost of producing a part is estimated to be $600. Find the optimal lot size.
Lot size
10
11
12
13
14
7
0.2
8
0.3
0.2
0.1
9
0.3
0.3
0.2
0.2
12
13
14
0.2
0.2
0.3
0.1
0.2
0.1
Example 5 Solution
R ( Q, x )
25 Q
x 0,...,8
1000x 25(Q x)
x 9,10
1000 10 25(Q 10) x 11,..., Q
x0
x0
10
x0
10
x9
x 11
x 11
n Pij Tij
Mj
H
ij
i 1
where Pij = production rate for product i on machine j (units/period),
Tij = processing time for product i on machine j (hrs./unit),
Hij = time units available per period for the processing of product i on
machine j (hrs.),
Mj = number of machines of type j required,
n = number of products.
Example 5
CIN-A1 Workcenters are used to produce three types of parts, {1, 2, 3}. Production rates
and unit processing times for the different items are given in the following table:
Item type
i
1
2
3
Production rate
Pi (units/day)
100
200
50
The facility operates one shift per day (8 hrs./day = 480 min./day). Determine the number of
workcenters required to meet production requirements.
Hi = min. available to process item i per day (Hi = 480 min.),
MA = number of workcenters.
3 Pi Ti
100 6 200 9 50 12
MA
Aj
H
ij
i 1
L-1
L-1
L-1
0
2
L
R
I&T
4
U-2
6
R
8
L-2
L-2
I&T
20
L-3
U-1
U-1
L-1
L-1
I&T
R
R
U-2
U-3
14
18
LEGEND:
I&T
U
12
16
U-2
I&T
10
I&T
U-1
L-1
I&T
U-2
O : Operator
M : Machine
L : Load
U : Unload
I : Inspection
T : Travel
R : Automatic run
: Idle time
The number of machine operators required depends on the number of machines tended
by one or more operators. The determination of the number of machines to be assigned
to one operator can take two approaches:
deterministic,
probabilistic.
A deterministic approach is to employ the multiple activity chart. This chart shows the
multiple activity relationships graphically against a time scale. The chart is useful in
analyzing multiple activity relationships, specially, when non-identical machines are
supervised by a single operator.
Let
at
ab
m n'
m(a b)
m n'
Tc
(a t ) m(a b)
I0
0
(1)
m n'
m n'
Im
Let
m n'
m n'
(2)
m n'
m n'
Note that
and
for m n,
for m > n,
where
m ()
m ()
TC(m) (),
TC(m) ().
(c1 n c 2 )(a t )
TC( n)
n n'
c
1c .
2
Example 6
7 25
3.73
7 158
.
TC(3)
m* = 3 machines/operator.
Example 6 (cont.)
b) For what range of values of machine cost per hour will the optimal assignment
determined in part (a) be economic.
TC(3) TC(4),
( 0.25 3 c 2 )(7 25)
(0.25 4 c 2 )(7 158
. ),
3
c2 $0.225/min. = $13.48/hr.
c2 0.225,
- Machine maintenance
- Plant services
Aisle Allowance
(Percentage of Net
Area Required)
5 10
10 20
20 30
30 - 40
In Example 7,
10
86
(20 10) 13.33 %.
12 6
Aisle Width
(ft)
12
11
10
9
6
5
3
6
8
Example 7
A planning department for the ABC Company consists of 13 machines that perform turning
operations. Five turret lathes, six automatic screw machines, and two chuckers are included in the
planning department. Bar stock, in 8-ft bundles, is delivered to the machines. The footprints for the
machines are 412 ft2 for the turret lathes, 414 ft2 for the screw machines, and 56 ft2 for the
chuckers. Personnel space footprints of 45 ft2 are used. Materials storage requirements are
estimatefd to be 20 ft2 per turret lathe, 40 ft2 per screw machine, and 50 ft2 per chucker. An aisle
space allowance of 13% is used. The space calculations are summarized in the table below.
2
Service Requirements
Workstation Quantity
Power
Compressed
Air
Other
Area (ft )
Floor
Loading
Ceiling
Height
Equipment
Material
Personnel
Total
Turret
Lathe
440 V
AC
10 CFM @
100 psi
150 PSF
240
100
100
440
Screw
Machine
440 V
AC
10 CFM @
100 psi
190 PSF
336
240
120
696
Chucker
440 V
AC
10 CFM @
100 psi
150 PSF
60
100
40
200
1336
174
1510
Food Services
Table 3. Shift Timing for 30 min.
Lunch Breaks
Beginning of
Lunch Break
11:30 am
11:50 am
12:10 pm
12:30 pm
End of
Lunch Break
12:00 noon
12:20 pm
12:40 pm
1:00 pm
Allowance per
Person (ft.2)
16 18
12 15
10 11
Area
Requirements
(ft.2)
500 1000
800 1600
1400 2800
2400 3900
3250 5000
4000 6000
5500 9250
Example 8
Statement:
If a facility employs 600 people and they are to eat in three equal 30 min. shifts, how
much space should be planned for the cafeteria with vending machines, serving lines, or
a full kitchen?
Solution:
If 36-in. square tables are to be utilized, Table 4 indicates 12 ft. 2 are required for
each of the 200 employees to eat per shift. Therefore, a 2,400 ft. 2 cafeteria should
be planned. If a vending area is to be used in conjunction with the cafeteria, an area
of 200 ft.2 should be allocated for vending machines. Thus, a vending machine food
service facility would require 2,600 ft. 2
A service line may serve 70 employees in the first third of the meal shift. Therefore,
three serving lines of 300 ft. 2 each should be planned. A total of 3,300 ft.2 would be
required for a food service facility using serving lines.
A full kitchen will require 3,300 ft. 2 for serving lines plus (from Table 5) 2,100 ft. 2
for the kitchen. Therefore, a total of 5,400 ft. 2 would be required for a full kitchen
food service facility.
Restrooms
Table 6. Number of Toilets Needed
for Number of Employees
Maximum Number of
Employees Present
at any One Time
1 15
16 35
36 55
56 80
81 110
111 150
Over 150
Minimum Number
of Toilets Needed
1
2
3
4
5
6
1 additional toilet
for each additional
40 employees
Number of
Employees
1 15
16 35
36 60
61 90
91 125
Over 125
1 100
Industrial
(Manufacturing
and warehouse
Facilities)
Over 100
Minimum Number
Of Sinks
1
2
3
4
5
1 sink for each
additional 45
employees
1 sink for each
10 employees
1 sink for each
additional 15
employees
RoughedoutLayoutMethod
Templatesormodelsareplacedonthelayouttoestimate
thegeneralconfigurationandspacerequirements.
RatioTrendandProjectionMethod
Onecanestablisharatioofsquarefeettosomeotherfactorthat
canbemeasuredandpredictedfortheproposedlayout.For
example,
squarefeetpermachine
squarefeetperoperator
squarefeetperunitproduced
squarefeetperlaborhour
Parking Space
( angular one-way )
( cross aisle )
( cross aisle )
( 900 two-way )
Automobile
Parking
Space Width
Parallel to the
Aisle (ft.)
45
45
60
60
75
75
90
90
Compact
Standard
Compact
Standard
Compact
Standard
Compact
Standard
10.5
12.0
8.7
9.8
7.8
8.8
7.5
8.5
Parking
Space Depth
Perpendicular
to the Aisle (ft.)
17.0
17.5
17.7
19.0
17.3
19.5
16.0
18.5
Aisle
Width (ft.)
Cross
Aisles
One-way
(ft.)
Cross
Aisles
Two-way
(ft.)
Parking
Space +
Aisle
2
Space (ft. )
11.0
13.0
14.0
18.0
17.4
25.0
20.0
28.0
12.0
14.0
12.0
14.0
12.0
14.0
12.0
14.0
22.0
24.0
22.0
24.0
22.0
24.0
22.0
24.0
236
288
215
274
203
282
195
276
Parking space
Width parallel to
aisle (9.8 ft.)
Parking space
Example 9
Problem Statement:
A new facility is to have 200 employees. A survey of similar facilities indicates that one parking
space must be provided for every two employees and that 35% of all automobiles driven to work are
compact automobiles. The available parking lot space is 180 ft. wide and 200 ft. deep. What is the
best parking layout?
Solution:
If the new facility were to have the same number of parking spaces as similar facilities, 100 spaces
would be required. Of these 100 spaces, 35 could be for compact automobiles. However, not all
drivers of compact cars will park in a compact space. Therefore, only 25 compact spaces will be
provided. A parking layout consisting of one-way traffic between five rows of 90 0 standard-sized
automobiles and one row of 900 compact automobiles would require a parking lot width of
5 (18.5) + 3 (28) + 1 (16) = 192.5 ft.
Similarly, four rows of 900 standard-sized automobiles, one row of 750 standard-sized automobiles,
and one row of 750 compact automobiles would require a parking lot width of
4 (18.5) + 2 (28) + 1 (19.5) + 1 (17.3) + 1 (25) = 191.8 ft.
which is too wide to be placed in a lot 180 ft. wide.
Example 9 (cont.)
Replacing the 750 aisle with a 600 aisle still requires 184.7 ft. Four rows of 900 standard-sized
automobiles, one row of 450 standard-sized automobiles, and one row of 45 0 compact automobiles
requires a parking lot width of
4 (18.5) + 2 (28.0) + 1 (17.5) + 1 (17.0) + 1 (13.0) = 177.5 ft.
This configuration will be utilized.
Leaving 24 ft. for two-way cross-aisle traffic at the front of the lot and 14 ft. for one-way cross-aisle
traffic at the rear of the lot, the 900 standard-sized automobile rows can each accommodate
19 automobiles
8.5
The last 900 standard-sized row does not require the 14 ft. one-way cross-aisle. Therefore, it accommodates
200 24
20 automobiles
8.5
The 450 standard-sized row can accommodate
13 automobiles
12.0
Example 9 (cont.)
The 450 compact automobile row is the first and does not require the 14.0 ft. one-way cross-aisle. It
can accommodate
200 24
10.5 16 automobiles
Hence, a total of
3 (19) + 20 + 13 + 16 = 106 automobiles
can be accommodated, with 15% being allocated to compact automobiles. The following Figure
illustrates the plan for the parking lot.
If the compact automobile row is replaced by standard-sized automobiles, the lot still fits within the
180 ft. 200 ft. configuration and 104 cars may be accommodated. Therefore, a decision must be
made regarding the advantages of providing compact automobile spaces versus not segmenting the
parking lot.