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52 views6 pages

IE475 - HW1 - Questions

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orselmerve2001
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IE 475: Facility Layout and Location (Fall 2024)

Department of Industrial Engineering, Abdullah Gul University

Homework 1

Instruction: All problems are with equal weights.


Due October 7, 2024 (Thursday at 11:59 pm)

Chapter 1:
1. What are the essential facility characteristics that should be
considered during the planning phase to achieve supply chain
excellence?

2. For an existing facility, draw a chart for the process of adding a


new operation.

3. What are the main two components of “facilities planning”? Write


up to 50 words to define each of them.

4. Why must the facilities planning be a continuing activity for any


organization?

5. What is the role of the facility planner if new equipment can be


introduced into a system without disrupting the ongoing activities?

6. List five facilities planning objectives.

7. Which is correct and why? “Any facility is typically planned only


once” or “Any facility is typically frequently replanned”.

8. How to evaluate the goodness of a facility plan in terms of costs?


9. Is facilities planning a strategic, tactical, or operational process,
and why?

10. Why does facility planning usually have a long-term impact?

Chapter 2:
1. What are the questions to be answered before developing alternative
facility plans?

2. What are the phases of “Process Desıgn” for facility planning?

3. What is the purpose of the “Activity Network Diagram”? Draw an


example.

4. Consider the following three-step manufacturing process:

• Assuming that demand is 1,000 units, what is the required input


to meet demand?
• Assume that the scrap cost per unit is $5 at process 1, $10 at
process 2, and $15 at process 3. Compute the total scrap cost for
the given system.

2
5. Consider the previous problem where, in this case, each process is
capable of rework. Given the information in the following table,
what is the input required to satisfy a demand of 1,000 units?

Chapter 3:
1. What is the definition of “Flow” in facilities planning, and what is
the difference between discrete and continuous flow processes?

2. What are the most common two objectives in the “material flow
system” and how to achieve them?

3. In a product department, list alternative flow patterns between


workstations (with illustrative drawings) and compare them.
(hint: focus on the relative arrangement of workstations to each
other)

4. When an automated material handling system is used in a


department, list alternative flow patterns between workstations
(with illustrative drawings) and compare them.

5. What are the common two criteria for establishing a production


department and determining its assigned workstations? Which is
better?

6. Draw a schematic example of a Job Shop layout consisting of five


departments.

3
7. Why determining the space requirements is a challenging task for a
facilities planner?

8. A local wood manufacturer wants to decrease material handling by


changing from a process layout to a GT layout. The machine-part
matrix for the wood manufacturer is shown below. Use the direct
clustering algorithm to form the cells.

9. A company produces four products in its production facility. The


facility has four departments labeled A–D. The routing
information, production quantities, and volumes for each product
are given in the table below. Determine the from-to chart.

4
Chapter 5:
1. What is the ultimate goal of the “facility planner” when designing
the material handling system?

2. What are the most common errors in “manual order picking” and
how can the material handling system designer eliminate them?

3. For ease of handling, the material handling system designer must


consider the material handling orientation. Give an example within
a manufacturing facility.

4. Materials should arrive at their destination in a manufacturing


facility on time (i.e., neither early nor tardy). Why?

5. For material handling system designers, what does the


“Standardization Principle” mean? Give an example.

6. After implementing the material handling system design, period


audits of the system performance should be conducted. Why?

7. In the material handling system design, using the “Material


Handling System Equation” is recommended. Why? What are the
six sets of question types in this equation and the role of each set?
Give only one example for each question type.

8. List the advantages of using the “Material Handling Planning


Chart”.

9. The “Material Handling Planning Chart” illustrates that both the


facility layout and material handling system must be jointly
designed. Explain.

5
10. Define the “unit load”. Give two examples of different unit load
designs.

11. Why does a relatively large unit load size require higher WIP
inventory?

12. Material Handling Designers should select containers with two


features: “Stackability” and “Nestability”. Explain each feature
and why they are important.

13. Give an example of the “progressive dimensions container


system”. What is the advantage of using this system?

14. What are the most two common objectives in the “Pallet Loading
Problem”?

15. What is the relationship between selecting the pallet design in a


facility and the international supply chain?

16. How does the “Pallet Pooling” system work? What is the
advantages of pooling?

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