INDUSTRIAL MANAGEMENT ENGINEERING SOCIETY

FACPLAD REVIEWER for Quiz 2

I. Fill in the blanks with the appropriate answer.

1. ALDEP means _____.

2. In a construction heuristic for QAP problem, if the _____ solution equals the lower
bound, then the solution is optimal.
3. Given an initial layout using MCRAFT, exchanging two non-adjacent and unequal size
departments is permissible because MCRAFT sweeps the band in _____ fashion.
4. This condition being applied to minisum location problem pertains to the optimum x-
coordinate will be such that no more than half of the total weights is to the left of x and
no more than half of the total weights is to the right of x.
5. In using CORELAP, _____ is being calculated to evaluate the location for a department.
6. The minimax location problem provides _____ because an analyst can locate a facility
within a line.
7. The maximum number of layout ALDEP can generate is _____.
8. The maximum number of iterations performed by MCRAFT is _____.
9. This model answers the questions what should be the layout in each period and to what
extent should changes be made in the layout.
10. A computer software layout that limits the number of bands to three and allows the
bandwidth to vary in every exchange.
11. The first tie-breaking rule using CORELAP is _____.
12. CORELAP’s _____ is the sum of the numerical values assigned to the closeness
relationships between departments.
13. MULTIPLE was developed by Bozer, _____, and Meller.
14. The maximum number of bands in BLOCPLAN is _____.
15. The layout generated by LOGIC is represented in _____ fashion.

II. Carry-on Baggage, Inc. manufactures carry-on luggage for airline travel. A new production plant
is being planned and a layout is to be designed. Six activities are involved in the process. The
layout of their current plant is shown in Figure 1. Furthermore, the expected flow matrix and
relationship chart for the new plant are shown in Table 1 and Table 2.

Table 1: Flow Data

F-T A B C D E F
A - 1 2 2 0 4
B 0 - 2 0 0 1
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FACPLAD REVIEWER for Quiz 2
C 2 0 - 0 3 0
D 0 1 0 - 0 0
E 0 0 1 2 - 1
F 3 1 2 0 3 -

Table 2: Relationship Chart

F-T A B C D E F
A - A I U U A
B - O E O E
C - X E I
D - A O
E - E
F -

A. NAS of the current layout: _____

B. Total cost of the current layout: _____

C. If CRAFT will be used, how many possible pair wise exchanges can be made if
Department E will be fixed in its current position (Enumerate them)? Develop an
improved layout (if there is one that exists) limiting to just one iteration and same area
requirements exchanges.

C.1 No of possible pair wise exchanges: _____

C.2 List of possible pair wise exchanges: _____
C.3 Draw and improved layout:

D. Using Hilbert Curve, develop an initial layout using MULTIPLE. Assume a layout vector
of CADBFE.

E. Apply ALDEP to develop a layout assuming a sweep width of 2. Start with Department
A. Each grid has a dimension of 2x2. Assume a minimum acceptable closeness rating of
U.

E.1 Sequence of departments to enter the layout: _____

E.2 Provide the Layout in the given space below:
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FACPLAD REVIEWER for Quiz 2

F. If LOGIC will be used to develop an initial layout, determine the dimensions (length and
width) of the departments assigned in the west side of the layout. Assume layout vector
of CADE at the east side and BF at the west side.

Fill in the table.

Department Length Width

G. If BLOCPLAN will be used to develop an initial layout, determine the new total cost and
the new efficiency rating. Assume three bands and a layout vector of CA-FE-BD.

G.1 New total cost: _____

G.2 New efficiency rating: _____

III. The ABC Auto Parts Company uses seven machines in their production. The current locations of
these machines are shown in Table 3. Furthermore, the pallet load movements per day between
the new machine and the ith existing machine, W1i, are given in the same table. The company is
planning to buy new machines and would like to d2etermine its appropriate location with respect
to the existing machines. 3

Table 3: List of Existing Machines

Machine Xi Yi Wi
1 8 7 100
2 13 2 100
3 13 13 150
4 18 10 100
5 2 10 200
6 8 16 250
7 18 20 100

A. Find the optimal location of the new machine that minimizes the maximum distance to be
traveled from/to the existing machines.

Optimal Location: _____

B. Find the optimal location of the new machine that minimizes total annual cost.

Optimal Location: _____

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FACPLAD REVIEWER for Quiz 2
Total Cost: _____

C. The company has identified 3 possible locations of the new machine as shown below.
Rank the alternative locations in order of preference using minimum rectilinear distance
with the optimal location in (B) as reference.

Fill in the table below:

Alternatives Xj Yj Rectilinear Rank

Distance
1 8 10
2 16 17
3 2 16

IV. Four departments are involved in the processing required for the product in a manufacturing
company. A summary of the material flow matrix (between departments – 1 to 4) and the four
available sites (from A to D, distances in meters) can be found in the matrices below. The
material handling cost is directly proportional to the distance traveled.

A. Determine the lower bound of the material handling cost. Based on the lower bound,
what should be the optimal assignment?

Lower bound: _____

Optimal Assignment: _____

B. Determine the material handling cost for the current layout design (1-B, 2-C, 3-D, 4-A)

Total Cost: _____

V. Suppose that four buildings are to be connected by electrical wires. The first two buildings are
circular: one at (1, 4) with radius 2, and the second at (9, 5) with radius 1. The third building is
square with sides of length 2 centered at (3, -2). The fourth building is rectangular with height 4
and width 2 centered at (7, 0). The electrical wires will be joined at some central point (Xo, Yo)
and will connect to building i at position (Xj, Yj). The objective is to minimize the amount of
wire used. Assume Euclidean Distance. Formulate this facility location problem as non-linear
programming problem.

Decision Variables:
Objective Function:
Constraints:
 INDUSTRIAL MANAGEMENT ENGINEERING SOCIETY
FACPLAD REVIEWER for Quiz 2
ANSWER KEY:

I. 1. Automated Layout Design Program

2. Dirty and quick
3. Serpentine
4. Median
5. Placing rating
6. Flexibility
7. 20
8. 4
9. DPLP
10. Blocplan
11. Largest area
12. TCR
13. Erlebacher
14. 3
15. Continuous

II. A. 0.3548
B. 340.50
C. C.1 7
C.2 BC, BD, AC, BF, DF, AD and CD
C.3 Improved Layout:
D.
D D D D B B B B
D D D D B B B B
A A D D B B F F
A A B B B B F F
A A A A F F F F
A A C C F F F F
C C C C F F E E
C C C C F F E E

E. E.1 Sequence of departments to enter the layout: A-B-F-D-E-C

E.2 Layout:

A A F F F F C C
A A F F F F C C
A A F F F F C C
A A F F F F C C
A A B B D D C C
B B B B D D E E
B B B B D D E E
B B B B D D D D

F.
Department Length Width
BF 7.5 B= 7.4667; F= 8.5333
CADE 8.5 C/A/D= 4.7059; E= 4
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FACPLAD REVIEWER for Quiz 2
G. G.1 314.035
G.2 0.7097

III. A. Optimal Location: (X1*, Y1*) = (11.5, 13.5)

(X2*, Y2*) = (15, 10)

B. Optimal Location: f(8, 10) or f(8, 11)

Total Cost: 8500
C.
Alternatives Xj Yj Rectilinear Rank
Distance
1 8 10 0 1
2 16 17 15 3
3 2 16 12 2

IV. A. Lower bound: 39

Optimal assignment: No optimal assignment

B. Total cost: 59