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 1 Shipping 2 Receiving 3 Office 4 Maintenance 5 Machining Area 1 6 Machining Area 2 7 Assembly Area 1 8 Assembly Area 2 9 Packaging Area 2000 2000 3000 2000 3000 3000 3500 3500 2000 Part A B C D E F Routing 2 5 6 7 1 2 7 9 1 2 6 7 9 1 2 5 7 8 9 1 2 6 1 2 5 1 Volume 400 200 400 200 200 100 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 1 THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 Answer 35 pts Flow between departments 1 2 3 1 2 3 4 5 6 7 8 9 4 5 100 700 6 200 600 7 400 200 400 200 800 8 9 800 200 600 200 Ranked Flow Values Departments 1 9 6 7 2 5 2 6 7 9 1 7 5 6 1 6 2 7 5 7 7 8 8 9 1 5 Flow Values 800 800 700 600 600 400 400 200 200 200 200 200 100 Layout 1 4 5 2 Optional Aisle 7 6 3 8 9 1 2 THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 Layout 2 4 5 2 7 6 1 8 9 3 Layout 3 4 5 7 6 8 2 3 9 1 3 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 4 THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 An alternative layout configuration Free area 8 Aisle 7 4 5 9 3 1 6 2 Road 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 5 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 a building that is 110 feet by 120 feet Do parts a and b of the problem Discuss the pros and cons of your layout design Answer 20 pts From To A B C D E F A x B C 13320 D 1800 9120 x E 6600 3120 6600 x 1200 x 5400 …