A cafeteria line would be an example of a process layout.
True
→ False
Process (functional) layouts allow greater flexibility in processing than product (line) layouts.
→ True
False
Product layouts achieve high utilization of labour and equipment.
→ True
False
A process layout is more susceptible to shutdowns caused by equipment breakdowns than a
product layout.
True
→ False
Process layouts tend to have low in-process inventories.
True
→ False
The design of factories and the design of warehouses are based on a similar set of factors.
True
→ False
Which of the following is not true about process layouts when they are compared to product
layouts?
lower maintenance costs
→ easier routing and scheduling
less investment in spare parts
less specialized equipment
all of the choices are true
Which one of the following is not considered an important factor in retail layout design?
→ cost minimization and product flow
presence of customers
traffic flow
opportunity to influence sales
The cycle time (CT) necessary in a product layout is determined by:
Number of workstations/sum of task times
→ Operating time per day/desired output per day
Number of workstations multiplied by the sum of task times
Operating time per day multiplied by desired output per day
A production line is to be designed for a job with three tasks. The task times are 0.3 minutes, 1.4
minutes, and 0.7 minutes. If the necessary cycle time is 1.2 minutes per unit, what is the
theoretical minimum number of workstations?
1.2
→ 2.0
2.4
3.4
none of these
The main issue in the design of process layouts concerns the relative positioning of:
workstations
processing components
→ departments
entrances, loading docks, etc.
manufacturing cells
A common goal in designing process layouts is:
minimizing the number of workers
minimizing idle time
→ minimizing transportation costs
maximizing work-station productive time
maximizing transportation distances
Problem 1 Page 229
An assembly line with 17 tasks is to be balanced. The longest task is 2.4 minutes, and the total time for all
tasks is 18 minutes. The line will operate for 450 minutes per day.
a. What is the minimum number of workstations needed if the output rate is to be 180 units per
day?
b. What cycle time will provide an output rate of 125 units per day?
c. What output will result if the cycle time is (i) 9 minutes? (ii) 15 minutes?
Solution
Longest task = 2.4 minutes
Total task times = 18 minutes
OT = 450 minutes per day
a. CT = 450 / 180 = 2.50 minutes per unit
N = 18 / 2.5 = 7.2, round to 8
b. CT = 450 / 125 = 3.6 minutes per unit
c i. output = 450 / 9 = 50 units per day
ii. output = 450 / 15 = 30 units per day
Problem 2 Page 229
A manager wants to assign tasks to workstations to achieve an hourly output rate of 33 units. Assume
that the shop works 60 minutes per hour (i.e., no breaks).
a. Assign the tasks shown in the following precedence network (times are on the nodes and are in
minutes) to workstations using the following heuristic rules: (i) “Assign the task with the most
followers.” (ii) Tiebreaker: “Assign the task with the longest time.”
Page 230
b. What is the efficiency?
Solution
Desired output = 33units per hour
Operating time = 60 minutes per hour
Operating 60 minutes per
time hr. = 1.82 minutes per
CT = =
Desired 33units per hr. unit
output
[2]
[No. of followers]
0.6
c [1]
0.5
[7] [6] [2] f [0]
1.4 0.5 0.7 0.5
a b d [1] h
1.0
g
[2]
0.8
e
Assign
Station Time left Eligible Will fit (time) Idle
1 1.82 a a a (1.4)
0.42 b -- 0.42
2 1.82 b b b (0.5)
1.32 c, d, e c, d, e e* (0.8)
0.52 c, d -- 0.52
3 1.82 c, d c, d d* (0.7)
1.12 c, g c, g c** (0.6)
0.52 g, f f f (0.5)
.02 g -- .02
4 1.82 g g g (1.0)
0.82 h h h (0.5)
0.32 0.32
1.28
* is tied in no. of followers, but is longer(longest)
** has more followers
b. Efficiency = 1 – [1.28 / 4(1.82)] = .82 or 82%.
Problem 4 Page 230
A large manufacturer of pencil sharpeners is planning to add a new sharpener, and you have been asked
to balance the assembly line, given the following task times and precedence relationships. Assume that
cycle time is 1.3 minutes per unit.
a. Do each of the following:
i. Draw the precedence network.
ii. Assign the tasks to workstations using the heuristic rule “Assign the task with the
most followers.” Break ties using the heuristic rule “Assign the task with the
longest time.”
iii. Determine the percentage idle time.
iv. Calculate the rate of output that could be expected for this line assuming a 420-
minute working day.
b. Answer these questions:
i. What is the shortest cycle time that will permit the use of only two workstations?
Identify the tasks you would assign to each workstation.
ii. Determine the percentage idle time that would result if two workstations were
used.
iii. What is the daily output under this arrangement?
Solution
1. CT = 1.3 minutes per unit
Time [no. followers]
.3 [3]
c
a. i .2 [4] .4 [3] 1.3 [2] 1.2 [0]
a b d
h
.1[3] .8[2] .3[1]
e f g
a. ii
Time Assign
Station left Eligible Will fit (time) Idle time
1 1.3 a, c, e a, c, e a* (.2)
1.1 b, c, e b, c, e b** (.4)
.7 c, e c, e c** (.3)
.4 d, e e e (.1)
.3 d, f -- 0.3
2 1.3 d, f d, f d** (1.3)
0.0 f -- 0.0
3 1.3 f f f (.8)
.5 g g g (.3)
.2 h -- 0.2
4 1.3 h h h (1.2)
0.1 -- 0.1
0.6
* most followers
** tied in no. of followers, but longer (longest)
Σ(idle time) .6
a. iii Percentage idle time: = = 11.5%
N × CT 4(1.3)
OT 420 min./day
a. iv Output: = = 323.1 units/day
CT 1.3 min./unit
b. Total time 4.6
i. Total time = 4.6 min., CT = = = 2.3 minutes.
N 2
Assign a, b, c, d, and e to workstation 1: 2.3 minutes
Assign f, g, and h to workstation 2: 2.3 minutes
ii. Percentage idle time = 0
OT 420
iii. Output = = = 182.6 units per day.
CT 2.3
