November 10, 2023

IE 323 – Production and Service Operations Planning I

Recitation 4

1. Consider the 8-parts, 11-machines data on the table given below.

a. Find any natural groupings of parts and machines. Suggest a set of part/machine groupings.

Part Sequence of Machines Visited Part Sequence of Machines Visited

1 2, 7 5 2, 7, 10
2 1, 4, 9 6 3, 7, 10, 11
3 1, 5 7 1, 9
4 6, 8 8 1, 6

Part / Machine 1 2 3 4 5 6 7 8 9 10 11
1
2
3
4
5
6
7
8

Part / Machine

Part / Machine
 November 10, 2023
Part / Machine

Part / Machine

b. Notice that one of the cells you formed in part (a), Cell 3, consists of the machines 2, 3, 7, 10 and
11 to produce the parts 1, 5 and 6. A forklift will transport the parts between machines thru the
center-to-center rectilinear aisles. The forklift can carry at most 40, 20, 25 units of parts 1, 5 and 6,
respectively. The cost per meter of a forklift is independent of the part in it.

The annual demand for each part and the area required by each machine are as follows:

Machine Area Required (m2)

Part Annual Demand Forklift Capacity for the Part 2 100
1 2000 40 3 100
5 500 20 7 200
6 1000 25 10 100
11 100

Find an initial layout on the sketch below which has 10mx10m grids. Calculate the total loaded
travel distance of the forklift.

10 m
10 m
 November 10, 2023
Machine

Step 1. Step 2.

Machine Number of loaded trips Machine Number of loaded trips

Step 3. Step 4.

Machine Number of loaded trips Machine Number of loaded trips

The initial layout is:

Loaded travel distance for 1 =

Loaded travel distance for 5 =
Loaded travel distance for 6 =
Total loaded travel distance =

c. Consider all possible pairwise exchanges (adjacent and nonadjacent) among machines in your
initial layout. While making an exchange, do not change the orientation of machines; use the
orientation in the initial layout. Perform the best exchange in terms of total loaded travel
distance and find a new layout.

1)
 November 10, 2023
2)

3)

d. Show the routings of the parts making up the family on the optimal layout.