GROUP 5(AC5A) – FACILITY LAYOUT

PROBLEMS

1. Use the longest task time rule to balance the assembly line described in Table. The line can
produce 30 units per hour.

Assembly-Line Task Information

Work Immediate Task

Element Predecessor Time(sec)

A None 25
B A 30
C A 15
D A 30
E C,D 40
F D 20
G B 10
H G 15
I E,F,H 35
J I 25
K J 25
Total 270

(1)What is the cycle time?

(2) What is the theoretical minimum number of stations?
(3) What are the resulting efficiency and balance delay percentages?

SOLUTIONS:

1) Cycle time = available time per hour/output per hour

= 3,600 seconds/hour
30 units/hr
= 120 seconds per unit

∑t
2) Theoretical minimum number of stations =
C
270 seconds
=
120 seconds per unit
= 2.25 or 3 workstations

3) Balance delay and resulting efficiency

 ∑t
Efficiency (%) = (100)
CxN
270 seconds
= (100)
3 x 120 sec /unit
= 75%

Balance Delay (%) = 25%

2. Fresh Foods Grocery is considering redoing its facility layout. The from-to matrix showing
daily customer trips between departments is shown in table 10-10, and their current layout is
shown in figure 10-12. Fresh foods is considering exchanging the locations of the dry groceries
department (A) and the health and beauty aids department. (F). Compute the ld score for Fresh
Foods’ current and proposed layouts. Which is better?

Table 10-10 From-to Matrix for Fresh Foods

Trips between Department
Department A B C D E F
A. Dry groceries - 15 45 25 10 50
B. Bread - 30 16 25 25
C. Frozen foods - 34 15 20
D. Meats - 40 10
E. Vegetables 20
F. Health and beauty aids -

Figure 10-10

A B C
D E F
Current layout for Fresh Foods

SOLUTION:

Proposed layout

F B C
D E A
 current proposed
l d ld l d ld
AB 15 1 15 15 2 30
AC 45 2 90 45 1 45
AD 25 1 25 25 2 50
AE 10 2 20 10 1 10
AF 50 3 150 50 3 150
BC 30 1 30 30 1 30
BD 16 2 32 16 2 32
BE 25 1 25 25 1 25
BF 25 2 50 25 1 25
CD 34 3 102 34 3 102
CE 15 2 30 15 2 30
CF 20 1 20 20 2 40
DE 40 1 40 40 1 40
DF 10 2 20 10 1 10
total 649 619

The proposed plant layout is better than the current because the ld is of the proposed layout is
less than the current layout which is better for the efficiency and effectiveness of the Fresh Foods
grocery.