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Efficient Transformation System Design Solutions

Explore exercises in Chapter 5 related to transformation system design, cost analysis, layout optimization, balancing lines, and task allocation.

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Efficient Transformation System Design Solutions

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  1. Solutions to Chapter 5 Exercises Chapter 5: Transformation System Design

  2. Exercise 1 7 5 1 2 3 6 4 4 X X X 5 X X 1 X X 3 X X 2 X X Components The cells are (M4, M5, M1, C7, C5,C1,C2) and (M2, M3, C3, C4, C6) Machines Chapter 5: Transformation System Design

  3. Exercise 2a A: 1-6 E: 1-3, 3-5 I: 4-5, 2-4 O: 1-2 1 3 2 6 5 4 Based on rectangular distances the cost of this layout can be calculated as follows: Chapter 5: Transformation System Design

  4. Exercise 2a - Cost of Shipping Between Departments(VD) Dept. 1: 4(2)+6(1)+2(3)+0(2)+7(1) = 27 Dept 2: 3(1)+5(1)+1(2)+3(3) = 19 Dept 3: 2(2)+6(1)+5(2) = 20 Dept 4: 5(1)+2(2) = 9 Dept. 5: 3(1) = 3 Total = 27+19+20+9+3 = 78 There may be better layouts. Chapter 5: Transformation System Design

  5. Exercise 2b - First Develop Cost Matrix Chapter 5: Transformation System Design

  6. Exercise 2bcontinued A: 1-3, 3-5, 2-4 E: 1-6, 4-5 I: 2-6, 3-6 O: 1-2, 2-3, 4-6, 5-6 There may be better layouts. 1 3 5 6 2 4 Chapter 5: Transformation System Design

  7. Exercise 3 - Distance Matrix for Current Layout Chapter 5: Transformation System Design

  8. Exercise 3 - Distance Matrix for Proposed Layout Notice that the only cost changes are between departments 1-2 and 1-6 since we are using rectangular distances. Chapter 5: Transformation System Design

  9. Exercise 3 - Current Costs 1-2: 40 daily trips ($.02)(10 ft.) = $8 2-1: 30 daily trips ($.03)(10 ft.) = $9 1-6: 40 daily trips ($.02)(30 ft.) = $24 6-1: 40 daily trips ($.02)(30 ft.) = $24 Total cost = 8 + 9 + 24 + 24 = $65 Chapter 5: Transformation System Design

  10. Exercise 3 - Proposed Costs 1-2: 40 daily trips ($.02)(30 ft.) = $24 2-1: 30 daily trips ($.03)(30 ft.) = $27 1-6: 40 daily trips ($.02)(10 ft.) = $8 6-1: 40 daily trips ($.02)(10 ft.) = $8 Total cost = 24 + 27 + 8 + 8 = $67 Chapter 5: Transformation System Design

  11. Exercise 3 Concluded • The proposed move is $2 a day more expensive, which amounts to $500 for the work year. • Hence, it should not be done. Chapter 5: Transformation System Design

  12. Exercise 4 • The important information in the table is • departments 1-3 should be very close • departments 5-6 should be very close • departments 2-3 should be very far • departments 3-5 should be very far • departments 2-4 should be close • departments 4-6 should be close • departments 1-4 should be very far Chapter 5: Transformation System Design

  13. Exercise 4 - First Trial O U A 6 5 1 X I X I A O I E I 3 4 2 O E X Major weakness of layout is that 1-2 are so far apart. Chapter 5: Transformation System Design

  14. Exercise 5 2 5 d b 5 4 f a 3 1 c e Chapter 5: Transformation System Design

  15. Exercise 5 continued Chapter 5: Transformation System Design

  16. Exercise 5 - Balancing the Line Using LOT Rule Chapter 5: Transformation System Design

  17. Exercise 6a Chapter 5: Transformation System Design

  18. Exercise 6a - LOT Rule (Ties Broken Alphabetically) Chapter 5: Transformation System Design

  19. Exercise 6b Chapter 5: Transformation System Design

  20. Exercise 6c • No. stations (min.) = 39/10 = 3.9 or 4 • Efficiency = 39/(4 x 10) = 98% Chapter 5: Transformation System Design

  21. Exercise 6c Time Eligible Task Station Available Tasks Assigned 1 10 a, b, h, g b 6 a, e, h, g h 2 a, e, g g 2 10 a, e a 3 c, d, e c 1 d, e e 3 10 d d 2 f f 4 10 i i Chapter 5: Transformation System Design

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