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Pitt IE 1055 - HW7-17 Solution

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1 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. IE 1055/2025 Homework 7 Due February 22, 2017 1. You are the facility design engineer in charge of the AJE production facility. Your current assignment is to develop a new facility layout for their Pittsburgh facility. The facility has the 9 departments listed below and currently has 6 products, A to F, with the monthly sales volumes and routings shown below. The facility has a total of 30,000 square feet with outer dimensions of 150 feet (vertically or North-South) by 200 feet (horizontally or East-West). (35 Pts) Department name Area Part Routing Volume 1. Shipping 2000 A 2-5-6-7-1 400 2. Receiving 2000 B 2-7-9-1 200 3. Office 3000 C 2-6-7-9-1 400 4. Maintenance 2000 D 2-5-7-8-9-1 200 5. Machining Area 1 3000 E 2-6-1 200 6. Machining Area 2 3000 F 2-5-1 100 7. Assembly Area 1 3500 8. Assembly Area 2 3500 9. Packaging 2000 Additional information - The office area includes space for management, engineering, sales, production control and other functions. The office area also includes the restrooms and a break area. - The two machining areas share some common workers who rotate back and forth between the two areas during a single shift. Similarly, the two assembly areas also share some common workers. - The volumes for the current products are expected to remain relatively stable with the exception of product D which may experience a significant increase in volume - a 300% increase - but this increase is uncertain. - There is an anticipation of introducing one new product within the next 3 years that will need to visit both machining area 1 and assembly area 1 and will have a volume of 300 units per month. - Assume that the necessary aisle space has been built into the area requirements for each department. But still indicate where the aisles would be in your facility. - There is a road that runs south of the building and assume that building access from the road is at the south side of the facility. - Assume that all individual units, types A to F, are equivalent to one pallet load. Deliverables - You need to develop a facility layout. You must clearly indicate the location for each department and indicate the locations of the main aisles (the ones for interdepartmental flow.) - You must justify your choice of locations for departments within the layout. Explain what tools you have selected to use in your design process and show charts, figures, etc. that you use.2 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. Answer (35 pts) Flow-between-departments 1 2 3 4 5 6 7 8 9 1 - 100 200 400 800 2 - 700 600 200 3 - 4 - 5 - 400 200 6 - 800 7 - 200 600 8 - 200 9 - Ranked Flow Values Departments Flow Values 1-9 800 6-7 800 2-5 700 2-6 600 7-9 600 1-7 400 5-6 400 1-6 200 2-7 200 5-7 200 7-8 200 8-9 200 1-5 100 Layout 1 4 3 7 5 6 8 9 2 1 Optional Aisle3 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. Layout 2 4 3 7 5 6 8 9 2 1 Layout 3 3 7 5 6 8 9 2 1 44 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. Layout justification: - Departments 1 and 2 are on the southern edge because material enters and exits the facility using these two departments and therefore both of them need direct access to the road. - Department 3 was placed on the road so that if visitors/customers come to the facility they can easily enter into a reception area. - The general flow of material is from department 2 - 5 - 6 - 7 - 8 - 9 - 1 and these departments have been arranged in a general U-shape following this flow pattern. - Note that expansion room has been left for each department. In particular department 5 since product D (which has anticipated growth) flows through 5 and the new product will also visit department 5. - Some expansion room has also been provided for department 6 although expansion does not seem as likely. The extra grids at the top are also there in order to permit a simple aisle across the tops of departments 5, 6, 7, and 8. - Departments 7 and 8 also have room to expand up in case D’s demand increases. Also, the new product will use department 7. - Department 4, maintenance, has been located so that it will not impede future expansion. It has also been kept close to departments 5, 6, 7, and 8 since those are the departments it is most likely to interact with. In particular, the machining departments, 5 and 6, may require more maintenance activity. Also note that department 4 was located above department 6 because department 6 is the department least likely to experience an increase in its production requirements in the future. - Note that there is a smooth and simple main aisle structure. - Layout option 2 may be preferable because the office area is placed in the corner which provides greater opportunity for later rearrangement of the production areas. Additionally, it may be possible for receiving and shipping to share the same set of loading/unloading docks. There is a slight loss of the U-shaped flow, but that loss is minimal. - Layout 3 is based on looking at future expansion and what the departments and aisle structure would look like after the new product is introduced and if demand for D grows.5 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. An alternative layout configuration: Free area Aisle Notes: - Departments 7 and 8, and departments 5 and 6 are located adjacent to each other because both departments share some common workers. - Departments 5 and 7 are located in the position where is easy to enlarge the departments for the new expected product. - Departments 8 and 9 are located in the position where there is room for expansion in order to serve the expected higher volume of product D. - Departments 1, 2 and 3 are located on the southern border of the facility due to the road running along that side and these departments should have good access to the road. 3 4 5 6 7 1 8 9 2 Road6 THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. 2. (20 pts) Use the data given in problem 6.8 but change the area of department B to 2100 square feet. Also, assume that the departments have the areas given but the shapes do NOT have to match the dimensions given. Assume the layout is for


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