Facility Layout

1. The layout of a job shop which has six departments is given below. The movement between departments is on rectangular paths:

   1	2	3
   4	5	6

   The number of trips between the departments in a month is given in the matrix below:

   	1	2	3	4	5	6
   1	-	50	750	950	250	500
   2		-	850	650	100	900
   3			-	150	450	400
   4				-	100	50
   5					-	300
   6						-

   The cost per unit distance per trip between departments (in Rupees) is given below:

   	1	2	3	4	5	6
   1	-	70	10	70	100	80
   2		-	90	30	50	60
   3			-	20	50	70
   4				-	40	10
   5					-	20
   6						-

   The distance between two adjacent cells is one unit. a) Determine the total cost of travel in a month. b) What will be the total cost if departments 3 and 4 are interchanged?
   Ans: a) Rs 5,76,500/- b) Rs 7,01,500/-
   
   
2. A toy car assembly requires the tasks and precedence relationships given in the table below. The desired cycle time is 50s. Use the largest candidate rule to assign tasks to workstations. Determine the line efficiency and balance delay.

   Task	Description	Predecessor	Task Time (s)
   A	Take and keep Baseplate	-	5
   B	Insert Front Axle	A	8
   C	Insert Rear Axle	A	8
   D	Fix front left wheel	B	15
   E	Fix front right wheel	B	15
   F	Fix rear left wheel	C	18
   G	Fix rear right wheel	C	18
   H	Fix steering	B	8
   I	Fix front seat	H	12
   J	Fix rear seat	G	14
   K	Take Body cover	-	5
   L	Fix top light on Body Cover	K	22
   M	Fix Body cover on Base plate	H, I, J, L	25
   N	Fix nameplate	M	10

   Ans: Station 1: A, B, D, E, K; Station 2: L, C, F; Station 3: G, J, H; Station 4: I, M, N. Line efficiency=91.5%. Balance delay=8.5%.

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